Patent Publication Number: US-2023160205-A1

Title: Layered Panels

Description:
FIELD OF THE INVENTION 
     The present invention relates to panels. More specifically, the present invention is a multi-layered construction panel. 
     BACKGROUND OF THE INVENTION 
     When it comes to construction panels, there are many different panels that are utilized in the construction industry. Depending on the project, different panels may be used to best fit the need of the specified project. Panels are typically constructed of high tensile sheets from many materials such as laminate, veneers, tensioned extrusions, etc. Panels are used ubiquitously in many applications and industries throughout the world. As construction and projects evolve and become more complex throughout history, it is important to innovate and update panels to the best quality in order to successfully and optimally to be used. 
     An objective of the present invention is to provide a lightweight panel comprising of multiple layers. The present invention provides a panel with the surface layers pinched at the edges to increase the strength and rigidity compared to standard existing panels. The present invention provide a strong, lightweight, aesthetic and antimicrobial efficacy panel. 
     SUMMARY 
     In accordance with the present invention, a novel layered panel that comprises a filler insert, a dense frame and a bond frame having at least one rectangular dense frame opening, a first external layer having a rectangular shape and a flat surface, and a second external layer having a rectangular shape and a flat surface. 
     In one embodiment, the first external layer includes at least one curved side edge; and the second external layer includes at least one curved side edge. 
     In another embodiment, the second external layer includes at least one pinched side edge. The one or more layers may be replaced with a single lightweight material such as composite, wood, or of the likes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is an exploded view of the present invention showing the different layers (a first external layer, dense frame, filler insert, bond frame, and second external layer). 
         FIG.  2    is an illustration of one embodiment of the first external layer of the present invention. 
         FIG.  3    is an illustration of one embodiment of the second external layer of the present invention. 
         FIG.  4    is an illustration of one embodiment of the second external layer of the present invention with a front curved surface and back curved surface. 
         FIG.  5    is an illustration of one embodiment of the dense frame of the present invention. 
         FIG.  6    is an illustration of one embodiment of the filler insert of the present invention. 
         FIG.  7    is an illustration showing one embodiment of the sloped sides of the bond frame of the present invention. 
         FIG.  8    is an illustration of one embodiment of a bottom surface of the bond frame with upwardly-extending bond frame walls. 
         FIG.  9    is a cross-sectional view of one embodiment of the present invention with a gap space. 
     
    
    
     DETAIL DESCRIPTIONS OF THE INVENTION 
     All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. 
     The present invention is to provide a lightweight panel comprising of multiple layers. The present invention provides a panel with the surface layers pinched at the edges to increase the strength and rigidity compared to standard existing panels. The present invention provides a strong, lightweight, aesthetic, and antimicrobial efficacy panel. The present invention comprises a first external surface, a dense frame, a filler insert, a bonding frame, and a second external layer. 
     In reference to  FIG.  1   , the present invention provides a layered panel  100  and is shown in an exploded configuration. The present invention provides a layered panel  100  made of five different layers. The five layers of the layered panel  100  are the first external layer  10 , the dense frame  20 , the filler insert  30 , the bond frame  40 , and the second external layer  50 . Layers can be placed on top of each other. The edges of the first external layer  10  can be attached to the dense frame  20  and the second external layer  50  can be attached to the bond frame  40  to form a layered panel  100  of the present invention. 
     The five layers method of construction can provide a higher degree of strength than a typical laminated board of the same materials but without the pinched edges. 
     The present invention is constructed with one or more frames (e.g., the dense frame  20 , the bond frame  40 ) and an inner lightweight core material (e.g., the filler insert  30 ). The one or more forementioned elements/components may be replaced with a single lightweight material such as composite, wood, or of the likes. 
     The first external surface  10  is the first exterior layer with an exposed high strength visual surface. 
     The dense frame  20 , shown in  FIG.  5   , can include a strong dense material with a high flexural modulus which help to maintain the flatness of the panel&#39;s surface. 
     The flexural modulus, determined from the slope of a stress-strain curve produced by a flexural test, is computed as the ratio of stress to strain in flexural deformation, or the tendency for a material to resist bending. 
     The higher the flexural modulus of a material, the harder it is to bend. A higher flexural modulus material, therefore, is stiffer than a lower flexural modulus material. In some embodiments, the present invention may include a dense frame having a flexural modulus of at least 10 GPa and a flexural strength of at least 90 MPa. 
     In some embodiments, the dense frame  20  may include at least one rectangular dense frame opening  26 . 
     The filler insert  30 , as shown in  FIG.  6   , can include a lightweight material such as foam, honeycomb, etc. 
     In some embodiments, the filler insert  30  can be a flat plane with an inner rectangular area  37  configured to fit in the dense frame opening  26  and/or the bond frame opening  46 . 
     The bond frame  40  can include any material that typically has bonding properties such as wood, plastic, composite, etc. 
     In some embodiments, the bond frame  40 , as shown in  FIG.  7   , may be of a rectangular shape and may include at least one bond frame opening  46 . The bond frame  40  may also include sloped sides  44 . 
     In some embodiments, as shown in  FIG.  8   , the bond frame  40  may include a plurality of upwardly-extending bond frame walls  45  defining the bond frame opening  46 . The height of the upwardly-extending bond frame walls  45  may be the same as the thickness of the bond frame opening  46 . 
     The second external layer  50  is the second exterior layer with an exposed high strength visual surface. 
     The first external surface  10  is a flat surface as illustrated in  FIG.  2   . In one embodiment, the first external surface  10  can be of a rectangular shape. 
     In reference to  FIG.  3   , the second external layer  50  of the present invention is shown. The second external surface  50  can also be of a rectangular shape and include pinched edges  60  outlining the rectangular shape of the second external layer  50 . In some embodiments, second external layer  50  can include a protruded surface  55 . 
     As can be seen in  FIG.  4   , in some embodiments, the second external layer  50  can include a front curved surface  56  and a back curved surface  57  create a stronger layered panel  100  with the benefit of a “soft” front/back edge. 
     In reference to  FIG.  9   , in some embodiments, the size of the second external layer  50  can be larger than the bond frame  40 . In such embodiments, a layered panel  100  of the present invention can include a gap space  65  between the bond frame  40  and the second external layer  50 . 
     The present invention introduces a panel that is constructed by using a lightweight interior with a high strength surface alongside compressed/pinched edges  60  and/or curved edges (front curved surface  56  and a back curved surface  57 ). With curving the edges after the pinched area (pinched edges  60 ), the present invention provides a stronger panel (layered panel  100 ) with the additional benefit of alternative aesthetics compared to existing panels. Note that the curved edges (the front curved surface  56  and the back curved surface  57 ) after the pinched area (pinched edges  60 ) may be positioned optionally on any number of edges of the layered panel  100 . 
     Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention.