Note: Descriptions are shown in the official language in which they were submitted.
CA 02353116 2001-07-13
PANEL SYSTEM HAVING SHAPED FOLD
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to U.S. Patent Application Serial Nos.
09/334,124,
filed June 15, 1999, and 09/360,444, filed July 26,1999, all of which are
incorporated herein
S by this reference -
FIELD OF THE INVENTION
The present invention is directed generally to panel systems and specifically
to panel
systems having decorative shapes.
BACKGROUND OF THE INVENTION
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 ofpanel
used in such
systems is a composite material sold under the trade name "ALUCOBONDTM". This
panel
has opposing exterior metal (aluminum) layers with a plastic layer
(polyethylene) located
IS or sandwiched between the metal layers. In some applications, panels have
been cut or
thinned along fold lines to permit the panel to be folded into desired shapes.
In other
applications, a stamping or press braking process (using top and bottom dies)
and a bending
process using a clamped pipe have been employed to produce panel shapes,
though at high
cost. Although many shapes have been constructed using such composite
materials, there
is a need for a method for manufacturing shapes in high volume at a low cost.
CA 02353116 2001-07-13
SUMMARY OF THE INVENTION
The panel system and method of the present invention can provide a series of
decoratively shaped folds or corners. The decoratively shaped folds or corners
use a shaping
member located adj acent 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. Stiffening members) may be
employed to
hold the shaping member rigidly or fixedly in position.
In one embodiment, a panel system for engagement with a structural member,
such
as a metal support beam or wall member, is provided that includes:
(a) at least one panel having a radiused fold; and
(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 members)
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.
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.
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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 S mm to about 500 mm and
more
typically from about 12 mm to about 112 mm. Typically, the inner fold radius
ranges from
about I 00 to about 5000% of the panel thickness and more typically from about
300 to about
2800% 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.
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 stricture.
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. Patents
5,809,729;
5,916,100; and 6,082,064, all of which are incorporated herein by this
reference.
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
IS 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.
The panel can be any suitable material. Examples include composite materials
such
as "ALUCOBONDTM", and "STEELOBONDTM", 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.
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In another embodiment, the present invention is a panel system that includes:
(a) one or more panels having one or more shaped folds;
(b) one or more perimeter extrusions engaging at least one peripheral edge of
the
panel(s);
S (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
(d) one or more stiffening members engaging the shaping rnember(s) on a
proximal end and a perimeter extrusions) on a distal end to hold the shaping
members) in
position against the interior surface. The shaping members) 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).
In another embodiment, a jig is provided for manufacturing the panel assembly.
The
jig includes:
(a) first and second substantially planar surfaces and
(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
therebetween.
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.
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In yet another embodiment, a method for manufacturing the panel assembly is
provided that includes the steps of:
(a) engaging one or more radiused shaping members) with a surface of a
panel(s); and
S (b) folding the panels) about the shaping members) to form a radiused fold
having at least substantially the same shape as at least a portions) of the
shaping member(s).
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 members) to hold the shaping members) in position.
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.
in yet a further embodiment, a method for manufacturing the panel assembly is
provided that includes the steps of:
{a) engaging one or more shaping rnember(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);
(b) folding the panels) about the shaping members) to form one or more folds
having at least substantially the same shape as at least a portion of the
shaping member(s);
and
(c) engaging one or more stiffening members) with the shaping members) and
the perimeter extrusions) to hold the shaping inember(s) in position against
the interior
surface.
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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
Figure I is a plan view of a panel milled along the center line of the fold;
Figure 2 is a plan view of the shaping member and stiffening members laid out
in
position on a flat panel (before folding);
Figure 3 is a side view of the fold showing the shaping member and proximal
end of
the stiffening member;
Figure 4 is another side view of the panel assembly when mounted on a
structural
member;
Figure 5 is a plan view of a stiffening member prior to folding;
Figure 6 is a perspective view of the stiffening member after folding along
the fold
lines;
Figure 7 is a perspective view of the proximal end of the folded stiffening
member;
Figure 8 is a perspective view of the distal end of the folded stiffening
member;
Figure 9 is a perspective view of the distal end of the folded stiffening
member
locked into position with a perimeter framing member;
Figure 10 is a perspective view of the proximal end of the folded stiffening
member
locked into position against the shaping member;
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Figure 11 is a perspective view of a plurality of completed panel assemblies
stacked
for shipping;
Figure 12 is a perspective view ofa completed panel assembly showing the
stiffening
members, shaping member, perimeter extrusions, and silicon sealant;
Figure 13 is a side view of the completed panel assembly showing the shaping
member, stiffening member, and perimeter extrusions;
Figure 14 is a perspective view of the completed panel assembly;
Figure 15 is a rear view of the fold of the completed panel assembly;
Figure 16 is a perspective view of a jig used to manufacture the panel
assembly;
Figure 17 is a side view of the panel assembly positioned in the jig during
manufacture;
Figure 18 is a perspective view of the jig showing the plungers, and
protective
covenng;
Figure 19 is a rear view of the jig;
Figure 20 is a plan view of a plunger;
Figure 21 is a perspective view of a cut and milled panel;
Figure 22 is another view of the cut and milled panel;
Figure 23 is a perspective view of the cut and milled panel after installation
of the
perimeter framing members;
Figure 24 is a perspective view of the panel assembly of Figure 23 with the
shaping
member and two stiffening members in position (prior to placement in the jig);
Figure 25 is a perspective view of the panel assembly of Figure 24 placed in
the jig
to form the fold;
CA 02353116 2001-07-13
Figure 26 is a perspective view of the panel assembly being forced into the
jig to
form the fold;
Figure 27 is a perspective view of the panel assembly after the fold is
formed,
showing the placement of additional stiffening members;
Figure 28 is a perspective view shoving the proximal end of a stiffening
member
' being knocked into position against the shaping member;
Figure 29 is a side view of a completed panel assembly showing the sealant
applied
to the stiffening members;
Figure 30 is a perspective view of the panel assembly in the jig; and
IO Figure 3I is another perspective view of the panel assembly in the jig
prior to the
assembly's removal.
DETAILED DESCRIPTION
The Panel Assembly
The panel assembly 100 will be described with reference to Figures 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.
The panel 104 can be composed of any suitable type of material, with a
composite
material sold under the trade name "ALUCOBONDTM" being preferred. As can be
seen
from Figure 1, the peripheral edges) of the panel 104 has a number of cut
lines (shown as
dashed lines I20) to permit the edge to be folded for engagement with the
perimeter framing
members. The panel further includes a flat milled strip I24 for the fold, with
the width "W"
of the strip being the desired length of the curvature of the fold.
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The perimeter framing members 108 can be of any suitable design, such as those
set
forth in U.S. Patents 5,809,729; 5,916,100; and 6,082,064. As noted, the
preferred design
is described in U.S. Patents 5,809,729; 5,916,100; and 6,082,064.
The stiffening members are depicted in Figures 5-10. Referring to Figure 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 128a,b on the distal end 132 of the stiffening member I
I2 for engaging
the interior face I36 of the perimeter framing memberl 08 on the panel edge
140 (see Figure
9), tabs 144a,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 Figure
I2), and radiused faces I60a,b also on the proximal end 148 for engaging the
interior face
164 of the shaping member i 16 (see Figure I0).
The shape of the exterior of the shaping member 116 is at least substantially
the same
shape as the radiused faces160a,b on the proximal end 132 of the stiffening
member 112.
Stated another way, in one configuration the curvature of the radiused faces}
I60a,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 I60a,b of the stiffening member 112.
As shown in Figure l, the stiffening member 1 I2 (which is typically formed of
the
same material as the panel) includes a pair of cut lines 168 (which are
typically formed by
a muter and are shown as dashed lines) about which the sides 172a,b of the
stiffening
member are folded as shown in Figures 6-8.
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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
S as having a circular shape, it is to be appreciated that any angular or
arcuate shape may be
utilized.
Referring to Figures 12-15, the perimeter framing members I08 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 .Tip
Referring to Figures 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 Iocated 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 I 16 to facilitate the folding and shaping
operation.
The first and second planar surfaces 205 and 206 typically form an angle "e"
between them. The angle a typically ranges from about 15 to about 135 degrees.
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 2 i 2 of the
jig 200 by displacement of the lever 232 (Figure 20).
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The jig surfaces 205 and 206 can include a protective material 236 (shown as
green
carpet in Figures I 8-20) 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.
Faam blocks 240 are located along edge 220 of the jig 200 to prevent the panel
from
contacting (and being damaged by) the plungers 21,6 during placement of the
panel in the
jig 200.
The Manufacturing Method
Referring to Figures 21 to 3 l, the manufacturing method will now be
described.
Referring to Figures 21 and 22, the panel i 04 is cut and milled for assembly.
The
I 0 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
~~ALUCOBOI~TDTM~~
panel. 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
1 ~ 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.
Referring to Figure 23, the perimeter extrusions 108 are cleaned, sealed, and
applied
to the panel by known techniques. As can be seen from Figure 23, no perimeter
extrusion
I08 is attached at or near the end of the strip 124. Otherwise, the fold could
not be made by
20 the jig 200.
Referring to Figure 24, two stiffening members 112a and 1 I2b are placed in
position
at either end of the panel I04 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
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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
S from each of the longitudinal edges 140 and 156 of the panel 104.
Referring to Figure 25, the partially completed panel assembly is next placed
in the
jig 200 with the perimeter framing member I 08 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.
Referring to Figure 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.
Referring to Figure 27, after the panel is fully folded and while the panel
assembly
is still in the jig the remaining two stiffening members 1 I2 are locked into
position (against
the perimeter framing members I 08 and shaping member I 16) in the central
portion of the
panel assembly. As shown in Figure 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.
As shown in Figure 29, the tabs 128 and 160 on the ends I32 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.
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Referring to Figure 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.
Referring to Figure 31, the stiffening members are adhered to the panel'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.
The now completed panel assembly may be removed from the jig and packaged for
shipping.
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.
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