Abstract:
Thin composite panels with interconnection schemes that are unitized with the panels, i.e., formed integrally and substantially simultaneously with the panels, and/or that are embodied by structural elements bridging a face sheet and a liner sheet of a panel. Further contemplated is the application of an injection molding technique, such as reaction injection molding, in establishing a foam or polymeric core between laminates in thin composite panels. Additionally contemplated is the use of interchangeable laminate components in affording the capability of altering the coloring or other visual features of a reveal in a panel or panels.

Description:
CROSS-REFERENCE TO RELATED U.S. APPLICATION  
       [0001]     This application is a continuation-in-part of U.S. patent application Ser. No. 10/342,155, filed on Jan. 14, 2003, the contents of which are hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention generally relates to thin composite architectural panels, and methods of making and assembling the same.  
       BACKGROUND OF THE INVENTION  
       [0003]     To date, thin composite architectural wall panels have been manufactured in multi-step processes which often involve both sheet manufacturers and panel fabricators. First, a thin composite sheet is manufactured by laminating metal skins to a plastic core. (An example of such a composite sheet is the “ALUCOBOND” material produced by Alusuisse Group, Ltd., Zurich, Switzerland.) Next, these sheets are typically shipped to a fabricator where they are cut to size and routed so as to return the edges around the perimeter. Typically, extrusions are fabricated and applied to the panel perimeter to create panel joinery. Also, stiffeners are typically applied in the field (i.e., the major flattened portion) of the panel to reduce the bowing of the thin panel under load. All of this tends to represent rather cumbersome and costly processes. (“Thin composite panel” and “thin composite architectural panel” are widely recognized as essentially interchangeable terms of art that relate to a specific genre of architectural panels, configured substantially as described above, whereby a thickness dimension as measured between opposing faces in the field of the panel can generally be between about 4 mm and about 6 mm, though a greater range of thicknesses, such as less than about 15 mm or less than about 10 mm are feasible.)  
         [0004]     Another currently available architectural panel product is embodied by a thicker composite foam panel which is made from metal skins sandwiching an insulated foam core. Such panels are widely known; examples thereof are disclosed, for instance, in U.S. Pat. No. 5,749,282 to Brow et al. Attendant manufacturing processes tend to be quicker and can involve lower manufacturing costs than with the conventional thin composite processes described above, but here manufacturing limitations do exist. An evolving need has thus been recognized in connection with imparting to the manufacture of thin composite panels a measure of ease and convenience typically enjoyed in connection with the manufacture of thicker composite panels.  
         [0005]     In view of the foregoing, there are specific aspects of conventional thin composite panels and their manufacture which appear to be ripe for improvement. One such aspect involves the schemes of interconnection between thin composite panels (i.e., the available connection arrangement at an interface between one thin composite panel and another). Historically, extruded interconnections of complex design have been utilized in such contexts, and such extruded interconnections have most often lent themselves to a manufacturing process completely separate from the manufacture of the panels themselves. Thus, a tremendous need has been recognized in connection with eradicating the associated inefficiencies in manufacture and possibly wasteful investment in separate materials.  
         [0006]     In the realm of providing a foam or polymeric (e.g., polyurethane) core to be sandwiched between laminates, conventional approaches have tended to emphasize poured-in-place processes that can often provide significant investments of time and resources to the process of manufacturing thin composite panels. A need has thus also been recognized in connection with providing a more efficient manner of establishing a foam or polymeric core in thin composite panels.  
         [0007]     Finally, history has seen various efforts made towards imparting distinct coloring or other supplementary visual features to a panel reveal. (A “reveal”, as generally known in the art, may be defined as a recessed region in the face of an architectural panel, and which may be disposed solely in one panel or defined between two panels, that itself normally lends a significant visual enhancement to a panel or building wall even without coloring or other supplementary visual features.) To date, it has generally been the case that only rudimentary methods have been contemplated for the purpose, such as, for example, the application of colored tape strips to a rear portion of the reveal. Accordingly, a need has been recognized in connection with providing a more effective and permanent method for imparting coloring or other supplementary visual features to a reveal.  
       SUMMARY OF THE INVENTION  
       [0008]     Generally, there are broadly contemplated, in accordance with at least one presently preferred embodiment of the present invention, various features for incorporation in the environment of thin composite panels that admirably address the problems discussed above.  
         [0009]     In accordance with an embodiment of the present invention, there are preferably provided schemes of interconnection between thin composite panels that are unitized with the panels, i.e., formed integrally and substantially simultaneously with the panels in question.  
         [0010]     In the context of the manufacture of thin composite panels, there is preferably provided in accordance with another embodiment of the present invention the application of an injection molding technique, such as reaction injection molding, in establishing a foam or polymeric core between laminates.  
         [0011]     There is also broadly contemplated, in accordance with another embodiment of the present invention, the use of interchangeable laminate components in affording the capability of altering the coloring or other visual features of a reveal in a panel or panels.  
         [0012]     Generally, there is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention a thin composite architectural panel comprising: a structural core; a set of laminates disposed about the structural core; a first portion for interfacing and facilitating interconnection with another thin composite architectural panel; a second portion for interfacing and facilitating interconnection with another thin composite architectural panel; the first interfacing portion comprising a first lip portion adapted to be interposed between a wall and a lip portion of another thin composite architectural panel in a building wall assembly; and the second interfacing portion comprising a second lip portion adapted to flank, with a wall, a lip portion of another thin composite architectural panel in a building wall assembly; whereby the introduction of a sealant between the first lip portion and a lip portion of another thin composite architectural panel is facilitated; whereby the introduction of a sealant between the second lip portion and a lip portion of another thin composite architectural panel is facilitated.  
         [0013]     Further, there is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention a thin composite architectural panel comprising: a structural core; a set of laminates disposed about the structural core; wherein the structural core has been introduced between the laminates via reaction injection molding.  
         [0014]     Additionally, there is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention a method of forming a thin composite architectural panel, the method comprising the steps of: providing a set of laminates; and introducing a structural core between the laminates via reaction injection molding.  
         [0015]     Furthermore, there is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention a thin composite panel comprising: a structural core; a set of laminates disposed about the structural core; at least one interchangeable component adapted to impart a pre-selectable appearance solely to a reveal associated with the panel.  
         [0016]     Yet further, there is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention a thin composite architectural panel comprising: a structural core; laminates disposed about said structural core; a first portion for interfacing and facilitating interconnection with another thin composite architectural panel; and a second portion for interfacing and facilitating interconnection with another thin composite architectural panel; said first interfacing portion comprising a first extension portion adapted to be interposed between a wall and an extension portion of another thin composite architectural panel in a building wall assembly; and said second interfacing portion comprising a second extension portion adapted to flank, with a wall, an extension portion of another thin composite architectural panel in a building wall assembly; said first and second interfacing portions comprising at least one connecting structural element disposed between at least one terminal portion of said face sheet element and at least one terminal portion of said major liner sheet element.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     The present invention and its presently preferred embodiments will be better understood by way of reference to the detailed disclosure herebelow and to the accompanying drawings, wherein:  
         [0018]      FIG. 1  is a plan cut-away view of conventional thin composite panels and an extruded connection therebetween;  
         [0019]      FIG. 2   a  is a schematic view of metal skin components of a thin composite panel;  
         [0020]      FIG. 2   b  is a close-up view of an interconnection between two thin composite panels using the metal skin components of  FIG. 2   a;    
         [0021]      FIG. 3   a  is a schematic view of alternative metal skin components of a thin composite panel, including an interchangeable component for imparting predetermined visual features to a reveal;  
         [0022]      FIG. 3   b  is a close-up view of an interconnection between two thin composite panels using the metal skin components of  FIG. 3   a;    
         [0023]      FIG. 4  schematically illustrates a panel manufacturing process; and  
         [0024]      FIG. 5  illustrates a variant panel embodiment.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0025]     As touched upon heretofore, thin composite architectural panels, also known as thin composite wall panels, are recognized in the art as normally encompassing a laminated composite including a polymeric or foam core sandwiched between two laminates, e.g., metal skins.  
         [0026]     Conventionally, sheets of a thin composite are fabricated by cutting them to size and bending their ends at right angles via routing. The panels are typically adjoined to one another, between bent ends, via extruded joining mechanisms. Shown in  FIG. 1  is such a conventional arrangement. As shown, two bent vertical thin composite panels  102  and  104  are joined at a vertical joint via an extruded connector indicated at  106 . (The relatively small thickness dimension of the panels  102  and  104  is to be noted, as starkly opposed to “thick” building panels whose thickness may extend, e.g., all the way back to a building structure as indicated at  108 .) Other components that may typically be provided include a pressure channel  110 , snap cover  112 , flange bolts/nuts  114  and a machine screw  118 .  
         [0027]     Though the extruded connector  106  shown in  FIG. 1  is of a particular configuration and size for the application at hand, such connectors of course have assumed other configurations and sizes as needed. Generally, it should be understood that a primary problem presented by such a connectors overall is that these are components formed in a separate process from the composite panels, thus necessitating a complicated procedure of first producing the panels, separately producing the extruded connector (conceivably to customized, and not necessarily universal, specifications), and then finally assembling the three components on-site.  
         [0028]     By contrast, there is broadly contemplated, in accordance with at least one presently preferred embodiment of the present invention, the absence of an extruded connection such as that shown in  FIG. 1 . More particularly, there is broadly contemplated in accordance with a preferred embodiment the use of metal sheet elements in forming a thin composite architectural panel and in providing effective joinery. Examples of metal sheet elements are indicated at  202 ,  204 ,  206  and  208 , schematically in  FIG. 2   a  and in more detail in  FIG. 2   b . The larger elements  202 ,  204  may preferably be roll-formed given their great extent, while the smaller elements  206 ,  208  could preferably be formed by a process such as via folding or a press-break. As shown, a face sheet  202  (i.e., that will be oriented externally and thus viewable on the exterior of a building wall) may preferably be integrable with liner elements  204 ,  206  and  208  (i.e., that will be disposed towards the interior of a building wall and thus will largely not be visible on the exterior of the building wall).  
         [0029]     As can be appreciated from  FIG. 2   a , metal sheet elements (which may alternatively be termed “laminates” or “laminate components”)  202 ,  204 ,  206 ,  208  can preferably be integrable with one another to create an interior space for the receipt of foam or polymer (e.g., polyurethane) in forming a structural core for a thin composite panel.  FIG. 2   b , on the other hand, affords a close-up view of an interconnection between two adjacent thin composite panels  201   a  and  201   b . It should be understood that  FIG. 2   b  can be representative either of a horizontal joint connection between two adjacent horizontal thin composite panels or a vertical joint connection between two adjacent vertical thin composite panels.  
         [0030]     The four metal sheet elements  202 / 204 / 206 / 208 , or laminates, depicted in  FIG. 2   a  are evident in  FIG. 2   b , though in  FIG. 2   b  they are not entirely shown with respect to both panels  201   a  and  201   b . As shown, face sheet element  202   a  of first panel  201   a  traverses flatly over a significant portion of the front of first panel  201   a  (i.e., has an ample module, or frontal dimension in the vertical direction with respect to  FIGS. 2   a  and  2   b , e.g. of about 57 inches or a little less) and then terminates at a return edge that may form the upper portion of a reveal  214 . On the other hand, major liner sheet element  206   a , that is by and large parallel to face sheet element  202   a , terminates by progressing inwardly towards the inner wall  212  and then, briefly, in parallel to wall  212  as shown. Liner element  208  essentially interconnects the terminal portions of elements  202   a  and  206   a  via an essentially parallel orientation with respect to portions of elements  202   a  and  206   a  as shown, and itself preferably terminates in a cross-sectional “u” adjacent inner wall  212  where it briefly overlaps the end portion of element  206   a.    
         [0031]     As shown with respect to second panel  201   b , a face sheet element  202   b  may preferably terminate here by progressing inwardly towards inner wall  212  and thence again in parallel with respect to inner wall  212 . Major liner sheet element  206   b  may preferably terminate similarly, although it will preferably extend virtually the entire distance to inner wall  212  before again running parallel with respect thereto. Liner element  204  is preferably configured to interconnect the terminal portions of elements  202   b  and  206   b  as shown, particularly, via briefly overlapping element both elements  202   b  and  206   b.    
         [0032]     It should be understood that, with reference to the embodiment depicted in  FIG. 2   b , panels  201   a  and  201   b  will preferably be configured similarly to one another over their entire extent.  
         [0033]     For the purpose of facilitating the interconnection of panels  201   a  and  201   b , and attachment fastener is preferably provided to attach panel  201   b  to inner wall  212  while sealant  218  will preferably be provided between liner elements  208  and  204  in a gap formed therebetween.  
         [0034]     When required, stiffeners (not illustrated), which are typically separate elements interposed between a thin composite and inner wall as known in the art, may be used to control cross-bowing of wide modules under suction loads.  
         [0035]     Sample dimensions with respect to the embodiment shown in  FIG. 2   b  may include a thickness a of between about 6 and about 8 mm in the major flat, frontal portion of each panel and a distance b of about 2 inches from the frontmost portion of each panel to inner wall  212 . Dimension c, or the frontal width of a reveal  214  formed between the panels  201   a / 201   b  can be customizably varied by appropriately configuring skin elements  202   b  and  206   b.    
         [0036]     The features and dimensions depicted and described with respect to  FIGS. 2   a  and  2   b  are of course merely illustrative and not restrictive with respect to the large variety of configurations that can be carried out within the scope of the present invention. Essentially, there is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention the eased manufacture and assembly of thin composite panels, via the use of customizable formed sheet elements such as  202 / 204 / 206 / 208 , as well as the eased interconnection of such panels via the optimized geometry and orientation of such components at their end portions. Thus, for instance, interconnection between panels in the embodiment shown in  FIG. 2   b  is facilitated by the interposition of a “u” portion (or lip portion)  220  of first panel  201   a  (afforded by liner element  208 ) between a “hump” portion (or lip portion)  222  of second panel  201   b  (afforded by liner element  204 ) and inner wall  212 , and providing sealant  218  in the gap therebetween. It will be appreciated that this affords a strong and rigid connection between panels  201   a  and  201   b , especially with the assistance of the anchoring effect provided by attachment fastener  210  with respect to panel  201   b.    
         [0037]     It will be appreciated that the use of roll-formed sheet elements in establishing the perimeter appears to lend itself to an easier and less costly scheme of interconnection between panels than in the case of extruded joinery (as in  FIG. 1 ).  
         [0038]     Among the unique advantages and features associated with panel products such as those contemplated in accordance with the embodiment of  FIG. 2   b  and related embodiments are an affordable architectural product with good flatness and wide modules. The result can also be that panels are provided which are integrable with other types of panel joinery in other types of panels, and with various accessories such as windows, trim extrusions and louvers. Conceivably, a wide variety of metal skins (or sheet elements) may be employed, such as aluminum, steel, copper, zinc and possibly many, many more. Another attendant advantage, as will be appreciated by those of ordinary skill in the art, is concealed-fastener, pressure-equalized joinery that utilizes dry seal technology.  
         [0039]     Another refinement of the present invention, as depicted in  FIGS. 3   a  and  3   b , involves forming a panel with external sheet elements that lend themselves to “reveals” having a distinct appearance.  FIGS. 3   a  and  3   b  are essentially similar to  FIGS. 2   a  and  2   b , respectively, except that reference numerals for similar components are advanced by  100 . Further, as shown in  FIGS. 3   a  and  3   b , a smaller face sheet element  303 , traversing a short extent in parallel with inner wall  312  at the rear of reveal  314  and configured to fit snugly over a shortened terminal portion of face sheet  301   b  while being accommodated by attachment fastener  301 , could-preferably be provided. This element  303  can be made from a different (and, by extension, differently colored) metallic material than other sheet elements ( 302   a / 302   b ) that are visible from the outside of the building wall, or could simply be of a similar material but colored differently. This then provides a reliable process for “colorizing” or otherwise adding distinct visual features to a reveal that is far more effective and durable than conventional processes such as providing colored tape at the rear of a reveal. The versatility of such an arrangement should also be appreciated, in that a set of elements  303 , providing different colors or visual features, could essentially be interchangeable or freely available to lend an appearance to reveal  314  as desired in the application at hand. Again, the embodiment illustrated in  FIGS. 3   a  and  3   b  is illustrative rather than restrictive; a wide variety of possible configurations are conceivable within the scope of the present invention that involve the use of interchangeable sub-components for selectably altering the appearance of a reveal.  
         [0040]      FIG. 4  schematically illustrates a manufacturing process in accordance with an embodiment of the present invention. As shown, skin elements such as those described and illustrated with respect to  FIGS. 2   a - 3   b  may be formed ( 402 ) and then arranged ( 404 ) in a mold. The mold is then preferably inserted into a press ( 406 ) for the receipt of a foam or polymeric (e.g., polyurethane) core material within the skin elements. The process of imparting the foam or polymeric core material may preferably involve injection ( 408 ) and, most preferably, reaction injection molding (or, “RIM”). RIM (e.g., as developed by the Bayer Corporation in Pittsburgh, Pa.) is used at present in the automotive industry (e.g., in forming automobile bumper systems), and has been found to provide surprising and advantageous results in connection with the formation of thin composite architectural panels. It has been found, particularly, that a RIM process is particularly well-suited to imparting a structural core into narrow and intricately shaped spaces such as those described, contemplated and illustrated herein. In view of an “aggressive” bond provided by an RIM process, structural integrity and strength are greatly enhanced, and this in turn leads to highly admirable weathering performance. If a RIM process is used to impart a polymeric core material, then the polymeric core material will preferably be thermal-set in view of the high temperatures associated with RIM.  
         [0041]     If a RIM process is used then, with reference to  FIG. 2   b , the core material may preferably be introduced into a cavity  224  that is of sufficient volume as to adequately accommodate the high-velocity introduction of core material. As shown, such a cavity  224  may be bound by different metal sheet elements (in this case, elements  202   b ,  206   b  and  204 ) and may have a significantly greater thickness than a majority of the panel. Here, for instance, cavity  224  could have a sample thickness dimension d of about 0.75 inch.  
         [0042]      FIG. 5  illustrates a variant embodiment. As shown, a thin composite panel  501  with face sheet  502  and liner sheet  506  may be interconnected not by further connecting liner elements as in  FIGS. 2   a - 2   b  but with structural elements  504  and  508 . Thus, at one end of panel  501 , particularly in the vicinity of attachment fastener  510 , face sheet  502  and liner sheet  506  can be bridged by a first connecting structural element  504 , while at the other end of panel  501 , face sheet  502  and liner sheet  506  can be bridged by a second connecting structural element  506 . Preferably, connecting structural elements  504 / 506  can be extruded elements, formed of a material such as aluminum. It should be understood and appreciated that these elements  504 / 506  are quite distinct from the extruded interconnection  106  shown in  FIG. 1 , and in fact function in a manner analogously to the connecting liner elements  204 / 206  in  FIGS. 2   a - 2   b , as will be better appreciated from the discussion below.  
         [0043]     Preferably, connecting elements  504  and  506  present features that permit them to be readily integrated with one another in assembling two or more panels together. As such, these features preferably also lend themselves to the same types of advantages discussed herein in connection with  FIGS. 2   a - 2   b . As shown, element  504  may include a first leg  520  that is essentially perpendicular to liner sheet  506 , a second leg  522  for being essentially parallel to a wall, and a third leg  523  that “returns” to meet a portion of face sheet  502 . A hook portion  524  may further extend from third leg  523  as shown. For its part, element  508  may include a first leg  526  that extends towards a wall from liner sheet  506 , a second leg (or pair of legs)  528  extending from first leg  526  and serving essentially as a continuation of liner sheet  506 , and a third leg portion  530  that extends away from leg(s)  528  to meet a hooked portion of face sheet  502 . Further, there may preferably extend from, an end of first leg  526  away from liner sheet  506 , one or more “fourth leg” portions (such as those shown and indicated at  532   a/b ) that essentially run parallel to a wall and may contact a wall.  
         [0044]     It should be appreciated that hook portion  524  functions analogously to the lip portion  222  discussed heretofore, and “fourth leg” portions  532   a/b  function analogously to the lip portion  220  discussed heretofore, with the same attendant advantages as discussed. Portions  524  and  532   a/b  can thus be considered, like lip portions  222 / 220 , to be “extension portions”. Sealant need not necessarily be provided between hook portion  524  and “fourth leg” portions  532   a/b.    
         [0045]     Of course, the features shown in  FIG. 5  are provided as non-restrictive and illustrative examples, and it should be appreciated that a connecting structural element  504  or  508  may be embodied in essentially any analogous manner that would provide a similar function as the particular elements  504 / 508  that are shown. For instance, “first leg”  520  may be eliminated in favor of an extension of liner sheet  506  that meets “second leg”  522 . It will be appreciated that the embodiment of  FIG. 5  and any embodiments analogous thereto essentially differ from  FIGS. 2   a - 2   b  in that, in the case of  FIG. 5  and embodiments analogous thereto, connecting elements other than connecting liner sheet elements are used to interconnect a face sheet and a liner sheet, while a similar degree of structural integrity is still provided. It is of course conceivable to provide a hybrid arrangement wherein, at one end of a panel, an interconnection such as  504  or  508  (or one analogous thereto) is provided at one end of a panel  501  while at the other end of panel  501  an interconnection is provided such as contemplated in connection with  FIGS. 2   a - 2   b  (i.e., involving connecting liner elements).  
         [0046]     In brief recapitulation, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a product which utilizes the economies of roll-formed edges of foamed-in-place (or poured-in-place) thicker panels and the highly desirable extreme flatness and wide module of a thin composite to offer a wide module architectural panel at reasonable cost. The panel can be made with a reaction injection molding RIM process and a high-density core material. Post-fabrication, as can be appreciated from the discussion herein, will very likely be minimal.  
         [0047]     Among the technical advantages associated with at least one presently preferred embodiment of the present invention are the advantages gained by intricate geometry at panel ends configured for permitting adjacent panels to cooperate and essentially interlock towards forming a complete wall system. Interconnection with adjacent panels is possible in view of the tremendous strength gained from the provision of a strong structural core between roll-formed sheets separated a small distance. If a RIM process is utilized as discussed heretofore, even more significant advantages of strength, structural integrity and weathering performance are gained. These represent tremendous advantages as compared with conventional poured-in-place processes.  
         [0048]     If not otherwise stated herein, it may be assumed that all components and/or processes described heretofore may, if appropriate, be considered to be interchangeable with similar components and/or processes disclosed elsewhere in the specification, unless an express indication is made to the contrary.  
         [0049]     If not otherwise stated herein, any and all patents, patent publications, articles and other printed publications discussed or mentioned herein are hereby incorporated by reference as if set forth in their entirety herein.  
         [0050]     It should be appreciated that the apparatus and method of the present invention may be configured and conducted as appropriate for any context at hand. The embodiments described above are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.