Abstract:
The present invention is directed to a panel system and manufacturing method in which a shaping member is used to form and support a similarly shaped fold in a panel. The shaping member can be held in position against the fold using one or more stiffening members.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    The present application claims the benefits under 35 U.S.C. §119(e) of U.S. Provisional Patent Application, Ser. No. 60/218,240, filed Jul. 14, 2000, which is incorporated herein by reference. The present application is related to U.S. patent application Ser. No. 09/334,124, filed Jun. 15, 1999, and Ser. No. 09/360,444, filed Jul. 26, 1999, all of which are incorporated herein by this reference 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention is directed generally to panel systems and specifically to panel systems having decorative shapes.  
         BACKGROUND OF THE INVENTION  
         [0003]    Panel systems are typically used to protect the exteriors of structures, such as office buildings, stores, and other business structures, from terrestrial fluids in the environment while providing an aesthetically pleasing appearance. A common type of panel used in such systems is a composite material sold under the trade name “ALUCOBOND™”. This panel has opposing exterior metal (aluminum) layers with a plastic layer (polyethylene) located or sandwiched between the metal layers. ALUCOBOND™ is typically used in facades because it is stable and yet flexible, weather-resistant, unbreakable, shock-resistant, and vibration absorbent.  
           [0004]    Panels are fabricated in a variety of two- and three-dimensional shapes. In some applications, panels, such as ALUCOBOND™ have been cut or thinned along fold lines to permit the panel to be folded into desired shapes. However, this process does not produce easily repeatable or symmetrical folds. In other applications, a stamping or press braking process (using top and bottom dies) has been employed to produce radiused folds, though at high cost. This type of press braking process requires the use of expensive equipment and is slow and time and labor intensive. In addition, this type of process cannot produce a bend with a small radius. The minimum achievable radius by the press breaking method is fifteen (15) times the thickness of the panel. Small radius bends can be produced through custom extrusion processes, using an extruded member as the fold that engages the panels and is located between the panels; however, these processes are even more expensive, time and labor intensive than the press braking process. In yet other applications, a bending process using a clamped pipe and a hinged form have been employed to form radiused folds. This process has, however, failed to produce repeatable and consistent results. Additionally, the minimum radius realizable by this process is similar to that realizable by the press braking process.  
           [0005]    Although many shapes have been constructed using such composite materials, there is a need for a method for manufacturing shapes in a repeatable fashion in high volume at a low cost. In addition, there exists a need to produce small radius bends in panels without resorting to custom extrusion processes.  
         SUMMARY OF THE INVENTION  
         [0006]    The panel system and method of the present invention can provide a series of decoratively shaped folds or corners, including small radius bends.  
           [0007]    In one embodiment, the decoratively shaped folds or corners use a shaping member located adjacent to a rear surface of the fold or corner to shape and support the fold or corner. The shaping member is typically left in position after the fold is formed and when the panel assembly is mounted on a structural member. In this manner, the shaping member helps the fold retain its shape after installation while also providing additional support to the fold or corner. Stiffening member(s) may be employed to hold the shaping member rigidly or fixedly in position.  
           [0008]    In another embodiment, a panel system for engagement with a structural member, such as a metal support beam or wall member, is provided that includes:  
           [0009]    (a) at least one panel having a radiused fold; and  
           [0010]    (b) one or more radiused shaping members contacting the interior surface of the fold and extending at least a substantial length of the fold. The radiused shaping member(s) can have any of a number of radiused shapes, such as a circular, elliptical, and parabolical shape. Where a number of shaping members are employed, the axes of symmetry of the members are typically parallel to the center line of the fold.  
           [0011]    The use of a shaping member permits the panel assembly to be manufactured inexpensively and in high volumes. The shaping member can provide a relatively simple manufacturing process and thereby eliminates labor intensive steps. The shaping member further ensures uniformity and consistency in the fold shapes and dimensions among manufactured panel assemblies. This is particularly important where panel assemblies are to be connected to one another along the edges intersecting the fold.  
           [0012]    The radius (outer and/or inner radii) of the fold can have a wide range of magnitudes. Typically, the radius of the fold ranges from about 5 mm to about 500 mm and more typically from about 12 mm to about 112 mm. Typically, the inner fold radius ranges from about 100 to about 5000% of the panel thickness and more typically from about 300 to about 2800% of the panel thickness. Thus, the inner fold radius can be less than 1500% of the panel thickness. As will be appreciated, the prior art press brake process typically can produce a fold radius of no less than 1500% of the panel thickness.  
           [0013]    In one configuration, each peripheral edge of the panel engages one or more perimeter framing members. As will be appreciated, perimeter framing members are employed to attach the panel system to the structural member of the structure. Any design of perimeter framing members may be employed that is suitable for the specific application. A preferred perimeter framing member design is described in U.S. Pat. Nos. 5,809,729; 5,916,100; and 6,082,064, all of which are incorporated herein by this reference.  
           [0014]    In one configuration, the panel system includes one or more stiffener supports or stiffening members spaced at intervals along the length of and contacting the shaping member to support and/or hold the shaping member in position. Typically, the stiffening members are anchored by being contacted at one or more ends with a perimeter extrusion. In most applications, the stiffening members contact a common perimeter extrusion at one or more ends of the members and the shaping member at another end of the supports.  
           [0015]    The panel can be any suitable material. Examples include composite materials such as “ALUCOBOND™”, and “STEELOBOND™”, and noncomposite materials such as metal sheets, and metal plates. To facilitate bending or folding, a portion of the panel material is typically removed, such as by a router, from the rear surface panel at and/or near the center line of the fold.  
           [0016]    In yet another embodiment, the present invention is a panel system that includes:  
           [0017]    (a) one or more panels having one or more shaped folds;  
           [0018]    (b) one or more perimeter extrusions engaging at least one peripheral edge of the panel(s);  
           [0019]    (c) one or more shaping members contacting the interior surface of the fold(s), extending a substantial length of the fold(s), and having at least substantially the same shape as the fold(s); and  
           [0020]    (d) one or more stiffening members engaging the shaping member(s) on a proximal end and a perimeter extrusion(s) on a distal end to hold the shaping member(s) in position against the interior surface. The shaping member(s) can have one of a radiused shape (e.g., circular, elliptical, and parabolical, etc. in shape), triangular shape, quadrilateral shape, and polygonal shape (e.g., pentagonal, hexagonal, heptagonal, octagonal, etc. in shape).  
           [0021]    In a further embodiment, a jig is provided for manufacturing the panel assembly. The jig includes:  
           [0022]    (a) first and second substantially planar surfaces and  
           [0023]    (b) a radiused corner located between the first and second substantially planar surfaces. The first and second substantially planar surfaces typically form an acute angle there between.  
           [0024]    In one configuration, the jig includes one or more plungers located at or near a peripheral edge of the first and/or second substantially planar surfaces to advance a panel towards the radiused corner and thereby cause the panel to be folded in the desired shape.  
           [0025]    In yet another embodiment, a method for manufacturing the panel assembly is provided that includes the steps of:  
           [0026]    (a) engaging one or more radiused shaping member(s) with a surface of a panel(s); and  
           [0027]    (b) folding the panel(s) about the shaping member(s) to form a radiused fold having at least substantially the same shape as at least a portion(s) of the shaping member(s).  
           [0028]    In one configuration, the method further includes, after the folding step, the step of placing one or more stiffening members adjacent to the panel surface and in contact with the shaping member(s) to hold the shaping member(s) in position.  
           [0029]    In one configuration, the method further includes, before the folding step, the step of engaging one or more perimeter extrusions with one or more edges of the panel.  
           [0030]    In yet a further embodiment, a method for manufacturing the panel assembly is provided that includes the steps of:  
           [0031]    (a) engaging one or more shaping member(s) with a surface of one or more panel(s), wherein one or more perimeter extrusions engage one or more peripheral edges of the panel(s);  
           [0032]    (b) folding the panel(s) about the shaping member(s) to form one or more folds having at least substantially the same shape as at least a portion of the shaping member(s); and  
           [0033]    (c) engaging one or more stiffening member(s) with the shaping member(s) and the perimeter extrusion(s) to hold the shaping member(s) in position against the interior surface.  
           [0034]    This summary is intended to be neither exhaustive nor limiting. As will be appreciated by those of ordinary skill in the art, the various features of the present invention can be combined selectively or collectively in a large number of different ways. These different ways fall within the spirit and scope of the present invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0035]    [0035]FIG. 1 is a plan view of a panel milled along the center line of the fold;  
         [0036]    [0036]FIG. 2 is a plan view of the shaping member and stiffening members laid out in position on a flat panel (before folding);  
         [0037]    [0037]FIG. 3 is a side view of the fold showing the shaping member and proximal end of the stiffening member;  
         [0038]    [0038]FIG. 4 is another side view of the panel assembly when mounted on a structural member;  
         [0039]    [0039]FIG. 5 is a plan view of a stiffening member prior to folding;  
         [0040]    [0040]FIG. 6 is a perspective view of the stiffening member after folding along the fold lines;  
         [0041]    [0041]FIG. 7 is a perspective view of the proximal end of the folded stiffening member;  
         [0042]    [0042]FIG. 8 is a perspective view of the distal end of the folded stiffening member;  
         [0043]    [0043]FIG. 9 is a perspective view of the distal end of the folded stiffening member locked into position with a perimeter framing member;  
         [0044]    [0044]FIG. 10 is a perspective view of the proximal end of the folded stiffening member locked into position against the shaping member;  
         [0045]    [0045]FIG. 11 is a perspective view of a plurality of completed panel assemblies stacked for shipping;  
         [0046]    [0046]FIG. 12 is a perspective view of a completed panel assembly showing the stiffening members, shaping member, perimeter extrusions, and silicon sealant;  
         [0047]    [0047]FIG. 13 is a side view of the completed panel assembly showing the shaping member, stiffening member, and perimeter extrusions;  
         [0048]    [0048]FIG. 14 is a perspective view of the completed panel assembly;  
         [0049]    [0049]FIG. 15 is a rear view of the fold of the completed panel assembly;  
         [0050]    [0050]FIG. 16 is a perspective view of a jig used to manufacture the panel assembly;  
         [0051]    [0051]FIG. 17 is a side view of the panel assembly positioned in the jig during manufacture;  
         [0052]    [0052]FIG. 18 is a perspective view of the jig showing the plungers, and protective covering;  
         [0053]    [0053]FIG. 19 is a rear view of the jig;  
         [0054]    [0054]FIG. 20 is a plan view of a plunger;  
         [0055]    [0055]FIG. 21 is a perspective view of a cut and milled panel;  
         [0056]    [0056]FIG. 22 is another view of the cut and milled panel;  
         [0057]    [0057]FIG. 23 is a perspective view of the cut and milled panel after installation of the perimeter framing members;  
         [0058]    [0058]FIG. 24 is a perspective view of the panel assembly of FIG. 23 with the shaping member and two stiffening members in position (prior to placement in the jig);  
         [0059]    [0059]FIG. 25 is a perspective view of the panel assembly of FIG. 24 placed in the jig to form the fold;  
         [0060]    [0060]FIG. 26 is a perspective view of the panel assembly being forced into the jig to form the fold;  
         [0061]    [0061]FIG. 27 is a perspective view of the panel assembly after the fold is formed, showing the placement of additional stiffening members;  
         [0062]    [0062]FIG. 28 is a perspective view showing the proximal end of a stiffening member being knocked into position against the shaping member;  
         [0063]    [0063]FIG. 29 is a side view of a completed panel assembly showing the sealant applied to the stiffening members;  
         [0064]    [0064]FIG. 30 is a perspective view of the panel assembly in the jig;  
         [0065]    [0065]FIG. 31 is another perspective view of the panel assembly in the jig prior to the assembly&#39;s removal;  
         [0066]    [0066]FIG. 32 illustrates a sectional view of the panel of FIG. 1; and  
         [0067]    [0067]FIG. 33 is a plan view of a stiffening member before assembly. 
     
    
     DETAILED DESCRIPTION  
     The Panel Assembly  
       [0068]    The panel assembly  100  will be described with reference to FIGS.  1 - 15 . The panel assembly includes a panel  104 , a plurality of perimeter framing members  108 , a plurality of stiffening members  112 , and a shaping member  116 .  
         [0069]    The panel  104  can be composed of any suitable type of material, with a composite material sold under the trade name “ALUCOBOND™” being preferred. As can be seen from FIG. 1, the peripheral edge(s) of the panel  104  has a number of cut lines (shown as dashed lines  120 ) to permit the edge to be folded for engagement with the perimeter framing members. The panel further includes a flat milled strip  124  for the fold, with the width “W” of the strip being the desired length of the curvature of the fold.  
         [0070]    The perimeter framing members  108  can be of any suitable design. The preferred design is described in U.S. Pat. Nos. 5,809,729; 5,916,100; and 6,082,064, all of which are incorporated herein by reference.  
         [0071]    The stiffening members are depicted in FIGS.  5 - 10  and  33 . Referring to FIG. 5, though the stiffening members can be composed of any rigid material and have any suitable design, the preferred material is the same as the material composing the panel and the preferred design includes tabs  128   a,b  on the distal end  132  of the stiffening member  112  for engaging the interior face  136  of the perimeter framing member  108  on the panel edge  140  (see FIG. 9), tabs  144   a,b  on the proximal end  148  of the stiffening member  112  for engaging the interior face  152  of the perimeter framing member  108  on the panel edge  156  (see FIG. 12), and radiused faces  160   a,b  also on the proximal end  148  for engaging the interior face  164  of the shaping member  116  (see FIG. 10).  
         [0072]    The shape of the exterior of the shaping member  116  is at least substantially the same shape as the radiused faces  160   a,b  on the proximal end  132  of the stiffening member  112 . Stated another way, in one configuration the curvature of the radiused face(s)  160   a,b  is at least substantially the same as the curvature of the interior face  164  of the shaping member. For a circularly shaped or cylindrical shaping member, the outer radius of curvature of the interior surface  164  of the shaping member is substantially the same as the radius of curvature of the radiused faces  160   a,b  of the stiffening member  112 .  
         [0073]    As shown in FIG. 1, the stiffening member  112  (which is typically formed of the same material as the panel) includes a pair of cut lines  168  (which are typically formed by a router and are shown as dashed lines) about which the sides  172   a,b  of the stiffening member are folded as shown in FIGS.  6 - 8 .  
         [0074]    The shaping member  116  can be of any suitable rigid or semi-rigid material, with a preferred material being a plastic such as PVC. Although a segmented shaping member or a series of shaping members can be used, it is preferred that a unitary or integral shaping member be employed for ease of manufacture. Although the present embodiment is shown as having a circular shape, it is to be appreciated that any angular or arcuate shape may be utilized.  
         [0075]    Referring to FIGS.  12 - 15 , the perimeter framing members  108  on opposing ends of the panel  104  and the stiffening members  112  hold (by contacting) the shaping member in position after the fold is formed.  
       The Jig  
       [0076]    Referring to FIGS.  16 - 20 , the jig used in manufacturing the panel assemblies will now be discussed. The jig  200 , is formed from a plurality of wood or metal structural members  204  and  208  which define first and second planar surfaces  205 ,  206 . A radiused corner  212  is located between and connects the surfaces  205 ,  206 . The radiused corner  212  typically has at least substantially the same shape curvature (e.g., the same radius of curvature) as the shaping member  116  to facilitate the folding and shaping operation.  
         [0077]    The first and second planar surfaces  205  and  206  typically form an angle “⊖” between them. The angle ⊖ typically ranges from about 15 to about 135 degrees.  
         [0078]    The jig  200  can include plungers  216  on one or both of the edges  220 ,  224  of the first and second planar surfaces  205 ,  206 , respectively. The plungers  216  have an extension  228  that moves laterally to force the panel against the radiused corner or nose portion  212  of the jig  200  by displacement of the lever  232  (FIG. 20).  
         [0079]    The jig surfaces  205  and  206  can include a protective material  236  to prevent the jig from scratching or damaging the exterior surface of the panel  104 . The protective material is typically a woven or carpet-type material.  
         [0080]    Foam blocks  240  are located along edge  220  of the jig  200  to prevent the panel from contacting (and being damaged by) the plungers  216  during placement of the panel in the jig  200 .  
       The Manufacturing Method  
       [0081]    Referring to FIGS.  21  to  31 , the manufacturing method will now be described.  
         [0082]    Referring to FIGS. 21 and 22, the panel  104  is cut and milled for assembly. The milled strip  124 , which runs lengthwise on the panel  104 , is caused by the removal of the rear metal layer. Thus, the milled strip  124  is the exposed plastic core of the “ALUCOBOND™” panel, shown in FIG. 32. Milling is typically done by a router. The depth of the router cut depends on the application but typically ranges from the thickness of the metal layer (which is typically about 0.020 inches) to about 50% of the thickness of the panel  104  (which is typically about 0.079 inches). As noted, the width of the strip is typically the arc or curvature length of the curved portion of the folded panel.  
         [0083]    Referring to FIG. 23, the perimeter extrusions  108  are cleaned, sealed, and applied to the panel by known techniques. As can be seen from FIG. 23, no perimeter extrusion  108  is attached at or near the end of the strip  124 . Otherwise, the fold could not be made by the jig  200 .  
         [0084]    Referring to FIG. 24, two stiffening members  112   a  and  112   b  are placed in position at either end of the panel  104  and the shaping member  116  is engaged with the radiused surfaces at the proximal end of each stiffening member. As will be appreciated, the length of the stiffening members is sufficient for the center line of the shaping member and the center line of the fold to form or define a plane that is at least substantially normal to the flat planar surfaces of the panel  104 . Stated another way, the center line of the shaping member and the center line of the milled strip  124  are offset at least substantially the same distance from each of the longitudinal edges  140  and  156  of the panel  104 .  
         [0085]    Referring to FIG. 25, the partially completed panel assembly is next placed in the jig  200  with the perimeter framing member  108  being positioned at or near the edge  224  of the planar surface  206 . In this orientation, the panel assembly is at least partially folded by the jig by being forcibly placed in the jig.  
         [0086]    Referring to FIG. 26 when the panel assembly is inserted into the jig  200 , the panel  104  is pushed or laterally displaced in the jig by the plungers  216 . As noted, the shape of the first and second planar surfaces and radiused surface (or jig nose) at least substantially match the desired or final profile of the panel.  
         [0087]    Referring to FIG. 27, after the panel is fully folded and while the panel assembly is still in the jig the remaining two stiffening members  112  are locked into position (against the perimeter framing members  108  and shaping member  116 ) in the central portion of the panel assembly. As shown in FIG. 28, the fit of the stiffening members is tight enough that a hammer may be required to rotate the stiffening members into the locked position.  
         [0088]    As shown in FIG. 29, the tabs  128  and  160  on the ends  132  and  168  of the stiffening members lock under the adjacent perimeter extrusions  108 , while pushing the shaping member  116  into the nose or fold of the panel. These interactions create a tight fit between the shaping member  116  and the panel  104  at the fold, thereby forcing the panel to retain the finished profile of the fold.  
         [0089]    Referring to FIG. 30, the distances “D” between adjacent stiffening members are preferably substantially equal so that the stiffening members substantially evenly distribute the forces to the fold in the panel. In this manner, the fold maintains a substantially uniform profile along its length.  
         [0090]    Referring to FIG. 31, the stiffening members are adhered to the panel&#39;s planar surface  280  using a suitable sealant/adhesive  284 , with silicon sealant being preferred. A bead of sealant is placed on either side of each stiffening member.  
         [0091]    The now completed panel assembly may be removed from the jig and packaged for shipping.  
         [0092]    While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the scope of the present invention, as set forth in the following claims.