CA2353116A1 - Panel system having shaped fold - Google Patents
Panel system having shaped fold Download PDFInfo
- Publication number
- CA2353116A1 CA2353116A1 CA002353116A CA2353116A CA2353116A1 CA 2353116 A1 CA2353116 A1 CA 2353116A1 CA 002353116 A CA002353116 A CA 002353116A CA 2353116 A CA2353116 A CA 2353116A CA 2353116 A1 CA2353116 A1 CA 2353116A1
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- CA
- Canada
- Prior art keywords
- panel
- shaping member
- fold
- perimeter
- shaping
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Panels For Use In Building Construction (AREA)
- Finishing Walls (AREA)
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
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.
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.
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.
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.
-2-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.
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.
-3-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.
(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.
-4-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.
(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.
-5-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;
' 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;
-6-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;
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.
_g_ 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.
_g_ 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).
-l0-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 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.
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.
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;
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.
_g_ 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.
_g_ 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).
-l0-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 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.
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.
Claims (31)
1. A panel system for engagement with a structural member, comprising:
at least one panel having a radiused fold; and a radiused shaping member contacting the interior surface of the fold and extending at least a substantial length of the fold.
at least one panel having a radiused fold; and a radiused shaping member contacting the interior surface of the fold and extending at least a substantial length of the fold.
2. The panel system of Claim 1, wherein the shaping member has one of a circular, elliptical, and parabolical shape.
3. The panel system of any of Claims 1-2, further comprising a plurality of stiffener supports spaced at intervals along the length of and contacting the shaping member.
4. The panel system of Claim 3, further comprising one or more perimeter extrusions engaging one or more peripheral edges of the at least one panel.
5. The panel system of Claim 4, wherein the plurality of stiffener supports each contact a perimeter extrusion.
6. The panel system of Claim 5, wherein the plurality of stiffener supports contact a common perimeter extrusion at distal ends of the supports and wherein proximal ends of the supports contact the shaping member.
7. The panel system of any of Claims 1 to 6, wherein the panel has at least one metal layer and at least one plastic layer.
8. The panel system of any of Claims 1 to 6, wherein the panel is metal.
9. A panel system for engagement with a structural member, comprising:
at least one panel having a shaped fold;
at least one perimeter extrusion engaging at least one peripheral edge of the at least one panel;
a shaping member contacting the interior surface of the fold, extending a substantial length of the fold, and having at least substantially the same shape as the fold; and a plurality of stiffening members engaging the shaping member on a proximal end and a perimeter extrusion on a distal end to hold the shaping member in position against the interior surface.
at least one panel having a shaped fold;
at least one perimeter extrusion engaging at least one peripheral edge of the at least one panel;
a shaping member contacting the interior surface of the fold, extending a substantial length of the fold, and having at least substantially the same shape as the fold; and a plurality of stiffening members engaging the shaping member on a proximal end and a perimeter extrusion on a distal end to hold the shaping member in position against the interior surface.
10. The panel system of Claim 9, wherein the shaping member has one of a circular, elliptical, parabolical, triangular, quadrilateral, and polygonal shape.
11. The panel system of any of Claims 9 to 10, wherein the panel has a plastic layer sandwiched between opposing metal layers and wherein one or the metal layers is at least partially removed adjacent to the shaping member.
12. The panel system of any of Claims 9 to 11, wherein a plurality of perimeter extrusions engage the peripheral edges of the panel.
13. The panel system of any of Claims 9 to 12, wherein the plurality of stiffener supports contact a common perimeter extrusion.
14. The panel system of any of Claims 9 to 13, wherein the proximal ends of the plurality of stiffener supports have at least substantially the same shape as the shaping member.
15. The panel system of any of Claims 9 to 10, and 12 to 14, wherein the panel has at least one metal layer and at least one plastic layer.
16. The panel system of any of Claims 9 to 10 and 12 to 14, wherein the panel is metal.
17. A jig for manufacturing a panel assembly, comprising:
first and second substantially planar surfaces and a radiused corner located between the first and second substantially planar surfaces.
first and second substantially planar surfaces and a radiused corner located between the first and second substantially planar surfaces.
18. The jig of Claim 17, wherein the first and second substantially planar surfaces form an acute angle therebetween.
19. The jig of Claim 17, further comprising 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.
20. A method for manufacturing a panel assembly, comprising the steps of:
engaging at least one radiused shaping member with a surface of a panel; and folding the at least one panel about the at least one shaping member to form a radiused fold having at least substantially the same shape as at least a portion of the shaping member.
engaging at least one radiused shaping member with a surface of a panel; and folding the at least one panel about the at least one shaping member to form a radiused fold having at least substantially the same shape as at least a portion of the shaping member.
21. The method of Claim 20, further comprising after the folding step:
placing at least one stiffening member adjacent to the panel surface and in contact with the at least one shaping member to hold the at least one shaping member in position.
placing at least one stiffening member adjacent to the panel surface and in contact with the at least one shaping member to hold the at least one shaping member in position.
22. The method of any of Claims 20 to 21, further comprising before the folding step:
engaging one or more perimeter extrusions with one or more edges of the panel.
engaging one or more perimeter extrusions with one or more edges of the panel.
23. The method of Claim 21, wherein at least one proximal end of the at least one stiffening member contacts the shaping member and at least one distal end of the at least one shaping member contacts a perimeter extrusion.
24. The method of Claim 23, wherein the at least one stiffening member has at least one second distal end in addition to the at least distal end and the at least one second distal end contacts a second perimeter extrusion that is different from the perimeter extrusion.
25. A panel assembly manufactured by any of the methods of Claims 20 to 24.
26. A method for manufacturing a panel assembly, comprising the steps of:
engaging at least one shaping member with a surface of at least one panel, at least one perimeter extrusion engaging at least one peripheral edge of the at least one panel;
folding the at least one panel about the at least one shaping member to form at least one fold having at least substantially the same shape as at least a portion of the at least one shaping member; and engaging at least one stiffening member with the at least one shaping member and the at least one perimeter extrusion to hold the at least one shaping member in position against the interior surface.
engaging at least one shaping member with a surface of at least one panel, at least one perimeter extrusion engaging at least one peripheral edge of the at least one panel;
folding the at least one panel about the at least one shaping member to form at least one fold having at least substantially the same shape as at least a portion of the at least one shaping member; and engaging at least one stiffening member with the at least one shaping member and the at least one perimeter extrusion to hold the at least one shaping member in position against the interior surface.
27. The method of Claim 26, further comprising after the folding step:
placing at least one stiffening member adjacent to the panel surface and rotating the at least one stiffening member into contact with the at least one shaping member and the at least one perimeter framing member.
placing at least one stiffening member adjacent to the panel surface and rotating the at least one stiffening member into contact with the at least one shaping member and the at least one perimeter framing member.
28. The method of any of Claims 26 to 27, further comprising before the engaging step:
engaging the at least one perimeter extrusion with the at least one peripheral edge of the panel.
engaging the at least one perimeter extrusion with the at least one peripheral edge of the panel.
29. The method of any of Claims 26 to 28, wherein the at least one stiffening member has at least one second end in addition to the at least one end and the at least one second end contacts a second of the at least one perimeter extrusion.
30. A panel assembly manufactured by any of the methods of Claims 26 to 29.
31. A method for manufacturing a panel assembly, comprising:
contacting a shaping member with a surface of a panel, the panel being connected to one or more perimeter framing members; and folding the panel around at least a portion of the shaping member to form a fold having at least substantially the same shape as the shaping member.
contacting a shaping member with a surface of a panel, the panel being connected to one or more perimeter framing members; and folding the panel around at least a portion of the shaping member to form a fold having at least substantially the same shape as the shaping member.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US21824000P | 2000-07-14 | 2000-07-14 | |
| US60/218,240 | 2000-07-14 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2353116A1 true CA2353116A1 (en) | 2002-01-14 |
Family
ID=22814314
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002353116A Abandoned CA2353116A1 (en) | 2000-07-14 | 2001-07-13 | Panel system having shaped fold |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20020020132A1 (en) |
| CA (1) | CA2353116A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113426931A (en) * | 2021-05-31 | 2021-09-24 | 尹春焕 | Antitheft rope processing equipment |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20100285294A1 (en) * | 2007-07-23 | 2010-11-11 | Sunrez Corporation | Sandwich panel end effectors |
| US8899000B2 (en) * | 2010-07-09 | 2014-12-02 | Birdair, Inc. | Architectural membrane and method of making same |
-
2001
- 2001-07-13 CA CA002353116A patent/CA2353116A1/en not_active Abandoned
- 2001-07-13 US US09/905,605 patent/US20020020132A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113426931A (en) * | 2021-05-31 | 2021-09-24 | 尹春焕 | Antitheft rope processing equipment |
Also Published As
| Publication number | Publication date |
|---|---|
| US20020020132A1 (en) | 2002-02-21 |
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