U.S. patent application number 09/963176 was filed with the patent office on 2002-12-05 for composite hybrid resin panels, molded parts and filler enhanced polymers therefor.
Invention is credited to Brignall, Thomas W. JR., Robinson, Michael G..
Application Number | 20020178672 09/963176 |
Document ID | / |
Family ID | 26928375 |
Filed Date | 2002-12-05 |
United States Patent
Application |
20020178672 |
Kind Code |
A1 |
Robinson, Michael G. ; et
al. |
December 5, 2002 |
Composite hybrid resin panels, molded parts and filler enhanced
polymers therefor
Abstract
A composite panel made of hybrid structural resins containing
fillers and reinforcing members for use in, but not limited to, the
construction and automotive industries. The panel provides superior
weatherability and excellent mechanical properties while achieving
various aesthetic appearances. The panel employs a multi-layer
composite construction. The panel is made of a weatherable outer
layer of hybrid resin, with a pigmented or graphic second layer
that may or may not contain reinforcing fillers suspended in hybrid
resin. The pigments in this second layer give the panel the outward
appearance desired, such as wood, granite, stone, metal, or other
appropriate cladding. The second layer is followed by at least one
structural layer of hybrid resin that may or may not contain
fillers and/or reinforcing agents. The panel may or may not have an
insulating core of foam, fiberglass, or similar insulating material
in order to achieve added R value.
Inventors: |
Robinson, Michael G.;
(Columbus, OH) ; Brignall, Thomas W. JR.;
(Marcellus, MI) |
Correspondence
Address: |
WM. CATES RAMBO
508 MERCANTILE LIBRARY BLDG.
414 WALNUT STREET
CINCINNATI
OH
45202-3913
US
|
Family ID: |
26928375 |
Appl. No.: |
09/963176 |
Filed: |
January 8, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60234890 |
Sep 25, 2000 |
|
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Current U.S.
Class: |
52/309.1 |
Current CPC
Class: |
B29K 2105/0032 20130101;
B32B 27/12 20130101; B44C 5/0423 20130101; B29L 2031/7232 20130101;
B29K 2995/0063 20130101; B32B 27/08 20130101; B44C 5/0453 20130101;
B29C 41/38 20130101; B29C 41/22 20130101; B29K 2105/0044 20130101;
B32B 3/30 20130101; E04F 13/18 20130101; B32B 27/06 20130101; B32B
2305/08 20130101; E04C 2/22 20130101 |
Class at
Publication: |
52/309.1 |
International
Class: |
E04C 001/00 |
Claims
What is claimed:
1. A self-supporting structural panel comprised of at least one
layer of high-density thermosetting hybrid resin, which is
sufficiently thick and strong to be self-supporting, said one layer
having an outer surface adapted to be visible, said layer
containing a UV blocker to protect the layer and subsequent layers
from the sun's UV radiation, adding to the weatherability of the
panel.
2. A panel according to claim 1, including at least one additional
high-density thermosetting hybrid resin layer adhered to the at
least one layer, the at least one additional layer containing at
least one additive of: a pigment and/or a graphic additive and/or a
filler or reinforcing additive.
3. A panel according to claim 2, including a reinforcing additive
in the at least one further layer, the reinforcing additive
comprising at least one of: fibers, microspheres, ceramic
particles, flyash, glass matt and/or reinforcing member.
4. A panel according to claim 2, including a graphic additive in
the at least one further layer, the graphic additive comprising
flakes with color for simulating stone.
5. A panel according the claim 4, wherein the flakes or granules
are made of acrylic.
6. A panel according to claim 1, including a structural element on
the inner surface of the at least one layer and at least one
additional layer of high-density thermosetting hybrid resin over
the structural element for encasing the structural element and
attaching the structural element and the at least one further layer
to the at least one layer.
7. A panel according to claim 6 wherein the structural element
comprises a grid element.
8. A panel according to claim 6 when the element comprises a
corrugated sheet.
9. A panel according to claim 6 when the structural element
comprises a sheet of fabric.
10. A panel according to claim 9 wherein a sheet of fabric is a
non-woven fibrous fabric having a pattern thereon.
11. A panel according to claim 1, including an outer layer element
embedded in the outer surface of the at least one layer, the outer
layer element being selected from the group consisting of
two-dimensional indicia, a two-dimensional pattern and a
three-dimensional surface texture material.
12. A panel according to claim 1, including a further layer of high
density, thermosetting hybrid resin connected to the inner surface
of the at least one layer, the further layer containing at least
one of pigment, a graphic component and a reinforcing component,
and a third layer applied to the further layer, the third layer
containing light-blocking pigment.
13. A panel according to claim 12 when the light-blocking pigment
comprises silver or black particles or pigments.
14. A panel according to claim 1, can include at least one recess
in the outer surface of the at least one layer for producing
indicia in the panel.
15. A panel according to claim 1, including at least one projection
on the outer surface of the least one layer for producing indicia
on the panel.
16. A panel according to claim 14, including pigmented hybrid resin
in the recess for producing a contrasting color in the, recess from
a remainder of at least one layer.
17. A panel according to claim 1 wherein the at least one layer is
clear.
18. A panel according to claim 17, including at least one
additional layer attached to the inner surface of the at least one
layer, the additional layer being made of high density
thermosetting hybrid resin and may contain at least one of a
pigment, a graphic component, and a reinforcing component, the
additional layer being visible through the one layer.
19. An apparatus for forming a self-supporting structural panel
comprising: a base; a ridge on the base defining an open pan mold;
and a means for spraying, pouring or injecting a two-component,
high-density thermosetting hybrid resin onto the pan mold to form
at least one layer of high density, thermosetting hybrid resin
which is sufficiently thick to be self-supporting.
20. A method of making a self-supporting structural panel
comprising: spraying two components of a high density,
thermosetting hybrid resin system into an open pan mold having the
shape of the panel to be formed, to build up at least one layer of
hybrid resin which is sufficiently thick and strong to be
self-supporting; and, including in the system a UV blocker for
blocking UV radiation from entering into the at least one layer.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to self-supporting structures
that can be used as curtain walls, fascia panels, and for other
structural purposes. The structures are either flat, textured or
three dimensional, and may be opaque or translucent. The panel is a
self-supporting, weather resistant, flame retardant panel
containing, or completely made up of, at least one layer of hybrid
resin that is sufficiently strong to act as an outer, weather
resistant, sunlight resistant, and mechanical-impact resistant
structure. Such a panel is particularly useful for exterior
building coverings, fascia, cladding, wall panels and the like.
[0002] Historically the architect has been left out of the loop in
favor of a designer who designed the building cladding to be
functional and aesthetically pleasing, then added signs onto a
building as requested by a client. The results in many cases were
less than pleasing. This "add-on" practice is one of the reasons
that most cities have passed sign codes and are making it harder to
just hang signs on a business. In many cases an architect is now
being asked to include signs and logos as part of the initial
presentation to the client and to consult with local code officials
to approve the project before it starts. Traditional signs are
being forced off these projects in favor of backlit canopies and
non-illuminated signs that are mounted flat on the walls of a
building. Clearly a new approach to this problem was needed. The
present invention allows a sign, logo, numbers, and names to be
built into a wall system. The panel can be molded to the same shape
and appearance as the building cladding, and can now be part of the
building element.
[0003] Panels currently being produced for wall systems range from
exterior insulating and finishing system (EIFS) Dryvit.TM. type
systems, metal panels, FRP, fiberglass reinforced cement, pre-cast
cement, thermo-formed plastic, roll formed metal, aluminum
composite material (ACM) and stone. These products are being
installed on buildings routinely. Most of the building panels used
today are two-dimensional, flat panels, with 90.degree. returns.
Many of these systems are heavy and require substantial framing
systems to support them. For the most part, these heavy panels
require a crane to lift into place. The most recognized systems
that can be three-dimensional are FRP and pre-cast concrete. FRP is
a short-lived material and, while pre-cast-concrete will last for
20 years or more, it is heavy and can be very costly.
[0004] Spranderal glass is also very popular as in-fill paneling.
Most of today's glass buildings are "curtain wall" with viewing
glass in the top and spanderal glass in the knee wall. Such a wall
system is flat and very common. Spranderal glass is an insulated,
thermo-pane, glass.
[0005] The present invention also allows a logo panel to be
installed as part of a fascia system used on a canopy, such as
found over the gas islands in a filling station, or on the front of
a cladding. The present invention can be made to match or contrast
with the building cladding or structure to achieve the desired
look.
[0006] Today, most plastic or polymer panels are thermoformed from
large sheets of acrylic or polycarbonate, or made of standard FRP
materials. For the most part these products reply on thickness to
provide the needed mechanical strength to withstand wind loads.
These products are heavy and expensive. Most of these products have
a poor coefficient of expansion and become brittle in very cold
weather. These products yellow with age and exposure to the Sun's
UV radiation. These products have served well, however, because
they are used in systems that hold and control their movement and
rely on UV inhibitors to make them weatherable.
[0007] Designers and engineers have wanted an alternate reinforced
product for years. The problem is that up to now there was no way
to provide a three-dimensional product (other than FRP and Cement)
that had the needed structure to withstand wind loads. Other
reinforced products on the market are laminated or coated fabric.
These products are strong for their weight but require a framing
system to provide tension on the material so it will withstand wind
loads and weather.
[0008] For many years FRP panels have been used in the building and
automotive industries. These panels are lightweight and have very
high mechanical strength, as well as being dimensionally stable
through a wide temperature range. The problem is that FRP panels
are short lived. The UV radiation from the sun tends to break down
the resin and expose the glass fibers to the elements. The present
invention solves this problem by employing an improved weatherable
surface of resin and hybrid resin in multi-layers. The subsequent
layers provide good mechanical strength and superior dimensional
stability through a wide range of temperatures and weather
conditions.
[0009] The present invention overcomes many problems related to
panels of the prior art and is sufficiently versatile to use for
signage, building and automotive panels, and for a variety of other
purposes.
1 REFERENCES CITED U.S. Pat. No. Date To Whom Granted Class
4,642,959 Feb. 17, 1987 Swiech, Jr., et.al. 52/311 5,070,668 Dec.
10, 1991 Lieberman. 52/309.9 5,266,234 Nov. 30, 1993 Ho, et.al.
252/182.27 4,201,003 May 6, 1980 With 40/545 5,020,252 June 4, 1991
DeBoef 40/564 5,070,668 Dec. 10, 1991 Leiberman 52/309.9 5,073,424
Dec. 17, 1991 Dressler 428/42 5,087,508 Feb. 11, 1992 Beck 428/195
5,215,699 June 1, 1993 Leiberman 264/225 5,225,260 June 6, 1993
McNaul, et.al. 428/40 5,345,705 Sept. 13, 1994 Lawrence 40/616
5,398,435 Mar. 21, 1995 Kanzelberger 40/1.5 5,423,142 June 13, 1995
Douglass, et.al. 40/605 5,443,869 Aug. 22, 1995 Harris 428/13
5,466,317 Nov. 14, 1995 Lause, et.al. 156/79 5,524,373 June 11,
1996 Plumly 40/600 5,655,324 Aug. 12, 1997 Siener, Jr., et.al.
40/615 5,633,063 May 27, 1997 King 428/71 5,794,402 Aug. 18, 1998
Dunlau, et.al. 52/783.17 6,023,806 Feb. 15, 2000 Dunlau, et.al.
14/73
SUMMARY OF THE INVENTION
[0010] One objective of the present invention is to provide a
structural, self-supporting panel, comprised of at least one layer
of high-density hybrid resin containing an ultraviolet (UV)
blocker; one that is sufficiently thick to provide an outer
weather-resistant and mechanically strong layer for the panel.
[0011] A further objective of the present invention is to
incorporate superior weathering and flame retardant characteristics
into additional hybrid resin layers, thus giving the panel a
sufficient flame and smoke rating for use as a curtain wall,
panels, cladding, or other building components. Class I or Class II
fire ratings are incorporated, depending on the end-use for the
panel.
[0012] Another objective of the present invention is to provide a
method for manufacturing the self-supporting hybrid resin panel,
which includes a high pressure spray, injection mold, a high
pressure open tool molding technique, a low pressure open tool
pouring technique, hand or machine mixing and casting technique, a
low pressure continuous machine casting process, and reaction
injection molding (RIM) technique.
[0013] The present invention can be practiced in a wide variety of
ways while taking advantage of the basic concept. Specifically the
outer surface is resistant to mechanical shock, resistant to
ultraviolet radiation from the Sun and weather, and is also
sufficiently flexible to be easily transported without damage and
sufficiently versatile so that any outward appearance, whether
flat, textured, or three-dimensional, can be provided to the
panel.
[0014] This can be achieved in many ways. Among these is a
technique of layering or spraying the hybrid resin material onto a
mold that may be flat or three-dimensional. Building up layer after
layer of the hybrid resin material, fillers, and other intermediate
materials as needed to impart characteristics of strength,
flatness, dimensionality mechanical, graphic, translucency or
opaqueness is then incorporated into the process, depending on the
end use of the panel. In this way the same invention can be
utilized to produce a wide variety of structures. The panels can be
used for sign fascias, or even for applying graphics in curtain
walls on buildings that are made from the panels. With appropriate
fire-resistance where necessary, strength and flexibility as
needed, and extremely long life as appropriate, they can be used
for building exteriors in particular.
[0015] One key to the present invention is that the first layer has
a weatherable surface. Products for exterior applications must
withstand heat, cold, precipitation and sun. Prolonged exposure to
the Sun's UV radiation is harmful to color and surface
characteristics such as gloss and texture. The UV blocker is a part
of the panel that further improves the weatherability of the first
layer of the composite.
[0016] The composite panels of the invention can be used for, but
are not limited to, the following for both interior and exterior
applications: architectural panels, exterior building elements,
in-fill panels in a curtain wall system, fascia panels, decorative
panels, equipment screens, rooftop structures, address or other
information signs, non back-lighted sign panels, logo panels, or
raised letters which are referred to as "channel letters" in the
sign art.
[0017] All panels made for these applications must have superior
weathering characteristics and can be flame retardant to Class I or
Class II, based on application.
[0018] The panel is thin and lightweight yet maintains structural
integrity so that it transfers wind loads to the structure or
curtain wall system to which it is attached.
[0019] The inventive panel is extremely versatile based on need,
and the flexibility of the molds. Tooling can be made of many
materials, wood, metal, silicon rubber, high temperature epoxy and
other filled compounds. Molds can be made in many parts to produce
a product that is three-dimensional, and with negative draft angles
and may have framing or attachment points held in place to become
part of the panel.
[0020] The mold can be made as a one-piece open pan, or as two
parts to produce a panel to a desired thickness or shape on the
back side as well as on the face of the panel. This includes
changes for multi-colors in the first and second layers. Tooling
may be of multi-pieces to allow negative draft angles and for
attachment points and hardware to be incorporated into the finished
product.
[0021] One technique for achieving the invention is to first spray
an initial layer of weatherable resin into the mold with a sweeping
back-and-forth motion to maintain uniform thickness. This layer has
no filler, but is sprayed to a thickness to achieve optimum UV
protection. One attribute of the present invention is that the
hybrid resin is formulated to cure very quickly--initially in a few
seconds--so that subsequent layers can be applied immediately
behind the first layer. This allows the entire composite to cure,
achieving a homogenous bond between layers.
[0022] A sweeping back-and-forth movement that is perpendicular to
the movement that was used to spray on the first layer applies to
the second layer. This has been found to drastically increase the
strength and flatness of the panel by crossing the orientation
direction of the resin and the fillers from one layer to the next.
The first and/or the second layer may also include pigment or solid
additives, such as fibers, flakes or particles, to achieve the
desired texture and color in the outer layers.
[0023] Advantageously, the first layer may be without these
additives so as to produce a clear, hard UV resistant finish of a
flame-resistant shell. If need be the second layer may include the
additives for decoration. Chopped fibers and fillers may be
included in the second and subsequent layers for drastically
increasing strength in a manner analogous to fiberglass reinforced
structures of the prior art (FRP technology). Fillers may include,
but are not limited to, micro-spheres, ceramic material, flyash,
glass fibers, glass scrim, Kevlar.TM. wire mesh, core materials,
and foam core.
[0024] For additional resistance to flexing or bending a structural
element or other reinforcing material can be included, such as an
egg crate or grid structure, wood, metal, or framing around the
perimeter. The reinforcing material may be installed behind the
first or second layer. Then a further layer of resin is sprayed
over the reinforcing element to encase and mechanically bond the
structural element to the remainder of the composite. Because of
the nature of the sprayed hybrid resin, each layer is intimately
adhered to the next without any possibility of de-lamination or
separation.
[0025] The mechanical strength, shock-resistance, fire-resistance
and UV-resistance for various panels constructed according to the
present invention have been demonstrated by a number of
industry-accepted tests.
[0026] In accordance with another embodiment of the invention, a
corrugated sheet of hybrid resin can be made using the same spray,
pouring, or molding technique of the invention, this sheet being
used as the structural strength-adding component incorporated into
the panel. This has the further advantage of being economical to
make and completely compatible with the rest of the hybrid resin
layers. The use of a corrugated layer also produces air pockets in
the panel that improve its thermal insulating characteristics.
[0027] In the remainder of this disclosure the term "hybrid resin"
is used interchangeably with urethane and polyurea, even though the
two are considered chemically separate from each other. Both
urethane and polyurea can be used, depending upon the application
of the invention, and in particular, the thickness of the single or
multiple layers needed in a particular panel structure. Both are
thermoset polymers and are acceptable for the present invention.
Thermoplastic panels are not appropriate although some
characteristics of thermoplastics, such as their good orientation
when extruded, are also characteristics of the present invention
where the orientation of the hybrid resin is utilized to improve
strength.
[0028] Among the attributes that can be incorporated into the
present invention is the use of a flame and/or smoke retardant
within the hybrid resin layer or layers. This gives the panel a
Class I or Class II, also known as Class A or Class B, fire rating
and a 15-year or longer life. Both the fire resistance and life
span of the invention have been confirmed by industrially accepted
tests.
[0029] Using appropriate inserts, such as a structural panel in the
form of an egg crate, a corrugated sheet, a honeycomb, a fiber mat
or other reinforcing sheets, appropriate bend-resistance can be
achieved. The panels can even be made bulletproof against small
arms fire by incorporating a layer of KEVLAR (a trademark of
Dupont). For some architectural requirements, such as buildings for
sensitive telecommunication equipment, bulletproofing is actually
specified as a requirement for an exterior wall of these equipment
buildings.
[0030] The present invention can also have comparable expansion
characteristics to that of FRP and, in fact, the expansion
characteristics can be tailored to a particular need.
[0031] The use of a UV blocker, is particularly advantageous. The
sufficient thickness of the hybrid resin layer containing the UV
blocker and pigments permits blocking of virtually all sunlight.
The thinner the layer, the less the blocking effect. UV blocking is
superior to UV inhibitors which, over the course of years, prevent
UV damage by undergoing chemical changes within the first layer of
the panel structure that produce an outward chalky substance on the
panel and normally increase its brittleness. No such deterioration
occurs in the present invention.
[0032] According to the present invention, the panel includes at
least one layer of hybrid resin and filler which is at least thirty
thousandths of an inch thick and preferably 30 to 60 thousandths of
an inch thick (30-60 mils). This gives the layer individually, and
the panel as a whole, self-supporting structural strength and
distinguishes it from hybrid resin and hybrid resin coatings used,
for example, on automobiles or other structures meant for outdoor
use. Generally, these coatings are no more than two to five mils
thick and, further, do not have the other attributes of the present
invention, such as fire-resistance, hardness and structural
strength.
[0033] The panel as a whole can be 0.060 to 0.250 inches thick for
skin or cladding and 0.250 to 4.0 inches thick for structural uses.
A letter panel or channel letter of the invention may have a depth
of 0.250 to 6.0 inches at its return (side wall). For this
disclosure the term channel letter includes not only
three-dimensional letters but also characters or symbols of any
kind such as numbers, logos, designs or any other shape to be
displayed.
[0034] The use of the spraying technique to manufacture a panel of
the present invention involves the mixing together of two
components to reactively form the high-density hybrid resin in a
spray head just before it is sprayed onto the mold. The mold itself
can be flat, have a surrounding ridge that forms a set back and
flange for the panel, and may include three-dimensional structures
onto which the hybrid resin is sprayed, such as lettering, logos
and any other three-dimensional shapes. Multiple layers can then be
built up behind the initial layer and, subsequently, the negative
impression of the letters, logos and other three-dimensional
structures can be filled in with coloring or decorative elements as
desired for the final product look. The spray technique can even be
utilized to produce simulated granite, marble or other graphic
effect.
[0035] Another technique is to paint the logo or lettering onto the
mold before the initial layer of hybrid resin is laid onto the
mold. This can be done using automotive grade hybrid resin, paint,
UVX, or other clear topcoat. The subsequent sprayed-on layer of
hybrid resin permanently encases the artwork into the outer layer
and then back layers can be applied as needed to provide desired
thickness, strength or other characteristics.
[0036] The spray head can be used with a third inlet, which mixes
structural fillers with the two parts that make up the hybrid
resin. The fillers can be fibers, particles of granite or acrylic,
flakes of granite, and/or other colored or non-colored fragments
that impart the desired appearance to the layer. A marble effect
can be achieved by swirling a combination of black and white
pigments in the actual spraying process for the first layer.
[0037] The fast curing of the invention makes it practical for
continuous use in a continuous or semi-continuous process. This
permits the application of layer-after-layer on a practical basis.
Where time is needed to lay up a second layer after an initial
layer has been applied, the curing time for the hybrid resin can be
tailored to decrease its curing time so that there is enough time
to apply subsequent layers before the previous layer has completely
cured. As noted above, cure times from two to twelve seconds are
possible, and this time can be increased if more time is needed to
apply back layers, fillers, or structural elements behind the
initial layers.
[0038] A typical fire retardant component to be added to the hybrid
resin is bromine. Bromine tends to reduce the structural strength
of the layer, however. It is generally desirable for curtain walls
of buildings to have a strength of about 3,000 to 3,500 PSI
(following ASTM standards). By adding bromine to achieve a Class I
or Class A fire rating, strength is reduced to about 2,800 PSI.
Strength can be increased again, however, by the addition of
subsequent back layers that incorporate glass or other reinforcing
agents behind the initial layer, thus achieving the overall
strength requirements for building purposes.
[0039] Graphic elements can also be laid into subsequent layers
where the initial layer is clear hybrid resin. For example, a sheet
of DAYCRON or TYVEK material (trademarks of Dupont) which adds a
wood grain or other desired appearance, can be laid behind an
initial layer and then a subsequent hybrid resin layer sprayed onto
the insert, permanently encasing it. This produces a panel with a
wood grain appearance in an-extremely economical and fast
manner.
[0040] In addition to spraying, casting or pouring of thicker
layers of hybrid resin into a mold can produce thicker, single
layer hybrid resin structures with or without graphic components of
any desired color. In accordance with another method and apparatus
of the present invention, the biased multi-layer spray application
can be used to produce long panels. As long as the cure times are
selected to give sufficient time to apply a second layer in an
edge-to-edge relationship to the previous layer, sheets of 60 feet
or longer maybe produced in this manner. This semi-continuous
technique can also be used with a filler sheet that is applied
between the sprayed-on layers. The filler sheet can also be used to
pull the panel as it is being manufactured. Alternatively, the
spraying-in of filler that is structural, graphic or both, can also
be utilized with this process.
[0041] As noted, reinforcing elements can be added to the panel.
Fiberglass can be inducted into the stream of resin that is sprayed
into the mold. Or, fiberglass matt can be precut and placed into
the mold as part of a layer or between layers. Other reinforcing
may-be added to achieve desired results. Graphic layers may be
added as a layer behind the first in mold coating and encapsulated
between first and second layers for both decoration and
reinforcing.
[0042] Many substances may be used as reinforcing agents such as,
but not limited to, corrugated paper, metal, wood, plastic
reinforcing, foam core, foam, microspheres, ceramic particles,
flyash, drywall, fire resistant board, metal sheets or plates,
honey comb or geometric shapes for strength or flatness. Wire mesh
for grounding or EM shielding, or electrical components as part of
an alarm system, and other items may be incorporated as needed for
specific applications.
[0043] Color may be added to the panels as well. Structural hybrid
resin may be pigmented in the polyol side of the system. This
allows the structural layers to be colored clear through. An
in-mold coating can be used to pigment the first surface. Pigments,
color chips, acrylic chips, photographic elements, graphic
elements, decals or color sheets can be encapsulated into the first
layer or between layers to be viewed from the front. Pigmenting is
based on hybrid resin paints and dyes that can be mixed into the
polyol.
[0044] The various features of novelty which characterize the
invention are pointed out with particularity in the claims annexed
to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages and
specific objects attained by its uses, reference is made to the
accompanying drawings and descriptive matter in which the preferred
embodiments of the invention are illustrated.
IN THE DRAWINGS
[0045] FIG. 1 is a perspective view of an open pan mold that can be
used in accordance with the present invention;
[0046] FIG. 2 is a perspective view of another pan mold of the
present invention;
[0047] FIG. 3 is a perspective view or a structural panel
constructed with the mold of FIG. 1;
[0048] FIG. 4 is a rear perspective view of a sign that can be
constructed with the mold of FIG. 2;
[0049] FIG. 5 is a view similar to FIG. 1 of another embodiment of
the mold;
[0050] FIG. 6 is a view similar to FIG. 5 of another embodiment of
the mold;
[0051] FIG. 7 is a perspective view of another embodiment of a mold
that can incorporate surface features on the finished panel;
[0052] FIG. 8 is a perspective view of a structural element that
can be used in combination with the panel of the present
invention;
[0053] FIG. 9 is a rear perspective view of a finished panel
constructed with the mold of FIG. 7;
[0054] FIG. 10 is a perspective view of a finished panel
constructed with the mold of FIG. 7;
[0055] FIG. 11 is a perspective view of another structural element
that can be used in accordance with the present invention;
[0056] FIG. 12 is a perspective view of a planar element that can
be used with the panel of the present invention;
[0057] FIG. 13 is a perspective view of a flexible non-woven and
printed fabric sheet that can be incorporated into the panel of the
present invention;
[0058] FIG. 14 is a schematic representation of an apparatus that
can be used to manufacture the structural panel of the present
invention;
[0059] FIG. 15 is a schematic view of a technique for laying down
initial and subsequent layers of the panel of the present
invention;
[0060] FIG. 16 is a schematic view similar to FIG. 15 showing the
manner of laying down a second and subsequent alternating layer of
the panel of the present invention;
[0061] FIG. 17 is a partial sectional view of one embodiment of the
panel of the present invention;
[0062] FIG. 18 is a sectional view of an open pan mold with a panel
of the invention therein;
[0063] FIG. 19 is a sectional view of another embodiment of the
panel of the present invention;
[0064] FIG. 20 is a sectional view of a still further embodiment of
the panel of the present invention;
[0065] FIG. 21 is a sectional view of a closed mold that can be
used in accordance with the present invention;
[0066] FIG. 22 is a schematic perspective view of an apparatus for
mass-producing a panel of the present invention;
[0067] FIG. 23 is a schematic sectional view of the panels of the
present invention used with a mounting system and as curtain walls
or exterior building elements for a building wall;
[0068] FIG. 24 is a schematic perspective view of the invention
used as a canopy sign;
[0069] FIG. 25 is a sectional view of a mold in an early step of
casting a panel or member according to the invention;
[0070] FIG. 26 is a top plan view of the mold of FIG. 25;
[0071] FIG. 27 is a view similar to FIG. 26 of the mold during a
subsequent step in the process;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0072] Referring to the drawings in particular, various embodiments
of the invention will now be disclosed.
[0073] General Panel and Mold Structure
[0074] FIGS. 3 and 4 illustrate two examples of the structural
panel of the present invention.
[0075] In FIG. 3, the panel generally designated 10 has a front or
visible surface 12 which is rectangular and has a 90.degree.
setback or return perimeter wall 14 and a peripheral flange 16
which can either be cut away in the finished panel or used to help
mount the finished panel. In FIG. 3, an optional reinforcing
element 18 is shown adhered to one of flanges 16. Reinforcing
element 18, e.g. of aluminum square tubing, may extend around the
entire perimeter of flange 16, or be provided on any one of the
setback sides or, as in the embodiment of FIG. 4, the panel
generally designated 20 can have no reinforcing element, but due to
its shape, thickness and construction is self-supporting. FIG. 4
illustrates the back surface of panel 20. Throughout the figures,
the same reference numerals will be utilized to designate the same
or functionally similar parts.
[0076] In the embodiment of FIG. 3, a recessed or negative indicia
22 is provided on the broad surface of panel 10 in the form of
words, logos or any other desired indicia. The space in the
negative indicia can be left free of material or may be filled with
other material, such as light-enhancing acrylic of contrasting
color to the panel 10.
[0077] A positive indicia 24 is provided in panel 20 as shown in
FIG. 4. This produces raised letters on the front side of the panel
(not shown in FIG. 4).
[0078] FIG. 1 illustrates an open pan mold generally designated 30,
which was used to manufacture the panel of FIG. 3 and FIG. 2
illustrates the pan mold 40 used to manufacture the panel of FIG.
4. Both pan molds are made up of a flat base 32, having a planar
upper surface that forms the broad front or visible surface of the
panel or sign. A border ridge 34 produces the perimeter of the sign
with the inner surface of ridge 34 forming the setback or return
surfaces 14 and a top surface of ridge 34 forming the flange 16.
Raised letters, channel letters or indicia 36 are fixed on base 32
in the selected position for making the negative indicia 22 in the
panel of FIG. 3. As shown in FIG. 2, negative or indented indicia
46 can be provided in base 42 to produce the raised or positive
indicia 24 of FIG. 4.
[0079] For ease of disassembling the panel from the mold after the
panel has been made, ridge 34 may be made of multiple, for example,
four separate parts which can be detached from mold base 32, to
ease the separation process.
[0080] FIGS. 5 and 6 show similar pan molds for producing positive
or negative indicia on a panel that is used with forwardly
extending setbacks, rather than rearwardly extending setbacks. FIG.
6, the positive indicia or plug elements 36 produce a forward,
rather than a reverse image, to produce a corresponding forward
positive image. In FIG. 5, the recessed 46 produces a forward
negative image in the finished panel.
[0081] FIG. 7 illustrates an open mold 30 where the exposed surface
of base 32 is provided with various features, such as a painted on
indicia 33; applied textural material 35, such as particles of
granite or colored acrylic; and a painted on pattern, such as a
marble pattern 37. With these different patterns applied to the
upper surface of base 32, and supplied in a manner to be released
from the upper surface of base 32, these textures and patterns are
imbedded in the upper surface of a resulting panel shown at 50 in
FIG. 10. Due to the nature of the present invention and the manner
in which the panels are created, the painted on indicia 33, texture
35 and pattern 37 are incorporated into the outer resin surface of
the panel 50. The entire surface of base 32 and the ridges of the
mold may also be coated with resin that is released from the mold
to coat the entire outer surface of the panel.
[0082] FIG. 8 illustrates a rectangular structural element 38 in
the form of a plastic grid or "egg crate", such as those used in
fluorescent ceiling fixtures. In accordance with the present
invention, after one or more initial layers of hybrid resin are
sprayed into the pan mold and before the resin cures, element 38 is
placed into the mold and then additional layers sprayed, poured, or
injected above or around it. This will greatly reinforce the
strength of the finished panel and completely incorporate the
structural element 38 into the panel as shown in FIG. 9 which is a
rear perspective view of the panel 50 which has been provided with
the structural element 38.
[0083] Other structural elements, such as a corrugated sheet or
resin, FRP, or metal 52 shown in FIG. 11, can be incorporated into
the layers of the panel. Sheet 52 can be made using the same spray
method of the invention, by spraying the hybrid resin system onto a
corrugated mold. FIG. 12 illustrates another element that can be
incorporated into the panel of the present invention, namely a
flexible non-woven printed fabric sheet 56 that in FIG. 12 has been
imprinted with a wood grain pattern. Since the first layer of the
panel is preferably clear, it sheet 56 is laid into the panel after
the first layer is installed and then embedded by installing
subsequent layers, the wood grain would be clearly visible on the
front surface of the panel. Since fabric sheet 56 is porous, liquid
hybrid resin impregnates the sheet and positively fixes it into the
layers of the panel.
[0084] Spray Technique
[0085] FIG. 13 illustrates a spray apparatus generally designated
60 which can be used to spray layers of the panel into the pan
molds of FIGS. 1, 2, 5, 6 and 7. Apparatus 60 includes a spray head
62 that contains a mixing chamber for receiving various components
of the thermosetting, high-density hybrid resin that forms the
structural panel of the present invention. The apparatus sprays
this mixture through a nozzle 64 which can be accurately directed
toward the mold either manually or with automatic equipment.
[0086] Apparatus 60 includes a first pressurized container 66, for
example, a 55-gallon drum containing a component "A", and a second
pressurized container 68 containing a component "B". Both
containers carry pressure pumps 70 and 72 that simultaneously
pressurize the containers and produce a metered supply of
components A and B along supply lines 71 and 73, respectively. The
components are actively mixed within the mixing chamber in the head
62. A propellant, such as compressed air, is supplied from a
compressor 74. This propellant that is labeled "D" may also be a
gas, such as CO.sub.2, or N.sup.2. A combination of air and
CO.sub.2 can also be used to insure that the mixed together
components A and B, after being thoroughly mixed, are applied with
sufficient force, e.g., 1500 PSI, in an atomized stream 76 which
can be accurately aimed and directed.
[0087] Additives "C", such as chopped fibers, pigment acrylic,
colored granules, flakes, or particles, flyash, ceramic
microspheres, or other additives, can also be supplied from an
additive container 78, under pressure of a pressurizing unit 80 and
along a line 81, to the mixing chamber in the mix head 62.
Alternatively, these additives can be evenly sprinkled into the
open mold after an initial layer has been applied to the mold and
before it cures. One particularly useful additive which lightens
and strengthens the dense hybrid resin of the second layer in a
panel, or other member of the invention, are microspheres, e.g.,
solid or hollow glass extender beads known by the name HGS-14 and
available from Larand Chemical Corp., of Hawley, Pa. This
particulate material is powder-like and flows freely. Average
particle size is 60 microns at 0.16 specific gravity. Another
reinforcing and/or filling material is a ceramic particle called
Dynamic Matrix. This filler is also flowable but rather than
spherical in shape the particles look like jacks on the order of
tens of microns in size. Flyash is yet another filler having many
of the properties of microspheres and ceramic particles.
[0088] As will be explained in greater detail later under a
separate section of this disclosure involving the chemistry of the
invention, components A and B may be supplied in approximately
equal parts by volume; and, in the shorthand notation of hybrid
resin chemistry, component A is known as the "iso" part, and
component B is known as the "polyol" part.
[0089] Various additives can be included in one or the other
component or part, such as curing catalysts, UV blocker, fire
retardant, e.g., bromine, and plasticizers. Additional catalysts
may be added to complete the cross-linking of the resin over any
carbon or oxides present in the flyash.
[0090] FIG. 15 illustrates an initial step for forming a single or
multi-layer panel of the present invention. In FIG. 15, spray head
62, which is embodied as a manual spray head with a handle and
trigger, is moved in a zigzag pattern 63 over the surface of mold
30 to lay down an initial layer 15, having hybrid resin chain
orientations that roughly mimic pattern 63. This produces an
orientation in the layer across the upper surface of mold 30.
[0091] Before layer 15 cures a subsequent layer 17 is applied as
shown in FIG. 16, but using a zigzag pattern 65 that is
substantially orthogonal to pattern 63. Subsequent layer 17, thus,
has an orthogonal orientation. Although the spraying pattern from
layer-to-layer need not be orthogonal, they should be at some
non-zero angle to each other to increase the strength of the
overall panel as the layers build up.
[0092] If the same composition is used for all layers, a monolithic
one-layer panel will result. If the composition is changed, for
example, by including a reinforcing additive in a subsequent layer,
a multi-layer panel is formed.
[0093] FIG. 23 illustrates an automatic apparatus 90 for
automatically applying the various layers of a panel of this
present invention onto a mold 30. In an initial zone 92, a first
automatic-spray head 62 can apply the first layer of clear hybrid
resin in pattern 63 of FIG. 15. In a second zone 93, a second
automated head 62 is used to apply hybrid resin, perhaps with
pigment in pattern 65 of FIG. 16.
[0094] In zone 94, an additional spray head 62 is used in
conjunction with an additive spray head 67 which is used to deposit
an even layer of additive, such as chopped glass fibers, colored
acrylic flakes or particles, or other reinforcing or decorative
additive to the layer applied in zone 94.
[0095] In zone 95, a further spray head 62 is used to apply a
final, rearmost layer to the panel that is now completed in mold 30
and allowed to fully cure. Mold 30 is moved from station to station
on a conveyer 82, which moves the mold in steps in the direction of
arrow 83.
[0096] Other Forming Methods
[0097] FIG. 21 shows an alternate mechanism for forming the panel
of the present invention, specifically a high or low-pressure mold
(RIM) having a male part 44, a female part 48, and raised or
recessed feature 45 in the panel 10 molded between the mold parts.
The hybrid resin components and additives are poured or injected
into the mold.
[0098] A mixing process and multistage mold can also be used
according to the present invention as illustrated in FIGS. 28 to
31. The Iso and Polyol components of the hybrid resin are modified
so that they can be used in a low-pressure machine mixer. This type
of system is known for use with low-density hybrid resin and pour
foams for both open and closed multi part cavity molds. Examples of
these machines that can be used with the present invention are the
Decker mixing machines available from Decker Industries of Port
Solarno, Fla., and a mixing machine available from Edge Sweets,
Grand Rapids, Mich. These devices can deliver a required amount of
hybrid resin into a mold to produce a multi layer product according
to the invention.
[0099] Some Uses for the Panel of the Invention
[0100] FIGS. 3, 4, 9 and 10 illustrate rectangular, substantially
flat panels which can be constructed according to the present
invention and which can be used for back-lit signs, curtain walls,
other exterior walls, free-standing signs and the like. The
apparatus of FIG. 24 can also be used to produce a continuous web
of the panel material.
[0101] One example for use of the present invention, especially
where part of the panel or all of the panel is transparent or
translucent, is as a backlit light box of a light box sign
schematically illustrated in FIG. 22. Panel 10 is attached over the
open front of light box 19 that contains a light source, such as
fluorescent tubes 21. The indicia carrying parts of sign 10 shown,
for example, at 22 may receive acrylic inserts or be painted with
shiny acrylic material and left transparent to light up the
indicia. The surrounding surface of the sign shown at 23 which can
be opaque is produced by flakes or grains of colored acrylic to
simulate granite or the like, and supplied in a subsequent layer in
the panel.
[0102] FIG. 25 illustrates use of a panel 10 as a curtain wall on a
structural building wall 25, for example, made of masonry. The
outer surface of panel 10 may simulate granite or other stone, or
may be decorative in another fashion. Indicia, such as logos or
words can be provided in one of the panels, for example panel 11.
In this way, the outer surface of the wall is uninterrupted but
still carries a lit decorative element to produce a highly unusual
and attractive appearance.
[0103] Using rectangular panels 10 and 11 having returns 14, the
panels can be attached to the wall using elongated unshaped rails
28, having inner facing teeth 41 which are biased toward the
building wall 25 to firmly retain the panels by biting into the
inner surfaces of the setbacks or returns 14. This is a very simple
mounting technique that is permitted by the low expansion
co-efficient of the panels of the present invention as well as
their weatherability, fire-resistance and UV resistance. Rails 28
are easily mounted to wall 25, e.g., by studs 43 fired by a stud
gun into the base of the rail.
[0104] Examples of the Panel Layers
[0105] FIG. 17 illustrates one embodiment of the structural panel
of the present invention. In this embodiment the outer, or visible
layer 1, is a clear thermosetting hybrid resin made in accordance
with the present invention that was sprayed using the technique of
spraying into an open mold. Behind this layer, a second clear resin
layer 2 was laid, on which acrylic flakes were encapsulated to
produce a granite appearance. The flakes were supplied from
container 78 in FIG. 14 in the form of colored acrylic flakes
having a color distribution to simulate stone such as granite,
marble, sandstone, limestone, stucco, ceramic tiles, brick, slate
and the like.
[0106] A subsequent layer 3 resin was applied to the still uncured
layer 2 to form a permanent seal and attachment to that layer.
Black or silver pigment may be used to produce an opaque layer. As
a further alternative, layer 2, rather than including granules, can
include chopped fiberglass and/or other fiber lengths or other
components to conduct heat energy away from the front surface and
increase the structural strength of the panel. FIG. 18 illustrates
a panel 10 made of a single built-up layer of resin containing
coloring to produce a panel with a single layer construction.
Despite the single layer construction, the thickness of resin can
be built up using the spray head 62, operating in orthogonal
directions as shown in FIG. 15 and 16 to maintain the flatness of
the panel and avoid warping or other deformation in the cured
panel.
[0107] FIG. 19 illustrates another embodiment of the invention that
includes the clear visible layer 1, a reinforced layer 2 and an
opaque layer 3. In the embodiment of FIG. 19, recesses 29 have
either been formed by plugs in the base of the mold or are machined
out of the surface of the panel after it has cured. These spaces
are filled with pigmented resin 31. Recesses 29 can be in the form
of logos, alpha/numeric characters or other indicia, and the panel
can be backlit. Light is amplified and dispersed by a light
dispersion panel 54, but the light is directed only to the elements
31 which light up on the surface of the panel. The remainder of the
panel can be provided with any desired color or texture by the
graphic and/or reinforcing features of layer 2.
[0108] FIG. 20 illustrates another panel of the present invention
which includes the outer clear layer 1, a pigmented layer 2, a
graphic particle-containing layer 3, reinforcing fabric 56, and a
rear insulating layer of low density urethane foam 39, with or
without fillers, which increases the R value of the overall panel
without reducing its strength, weatherability, fire-resistance or
other advantageous characteristics.
[0109] Two types of microspheres can be used with the invention.
One is hollow (e.g. HGS-14) and is also called micro balloons, and
is added to increase strength and reduce weight and thus cost,
since resins are sold by the pound. The second are solid
microspheres. Flyash or other extenders can also be used to make
the panel denser.
[0110] With these additional factors in mind, another panel of the
invention has a first layer about {fraction (3/16)} inches thick
and made of hybrid resin (explained in greater detail later in the
disclosure), on which a second layer of hybrid resin containing
about one third part by volume HGS-14 micro balloons. The result is
light yet very flat and strong. Dynamic Matrix ceramic particles
can replace the micro balloons. In another embodiment of the
invention flyash particles can replace these fillers.
[0111] A further example of the invention has a first 1/8 inch
thick layer of hybrid resin and a second layer about 3/8 inches
thick of closed cell, eight-pounds-per-cubic-foot density foam. The
conventional foam, for example a three-pounds-per-cubic-foot hybrid
resin foam sold by Burton under the name BUC 152, is open celled
and does not add appreciable strength or insulation as does the
foam used with the present invention.
[0112] A still further example of the invention is a three layer
hybrid resin structure having a first white layer, about 0.030
inches thick of UV blocked automotive grade urethane, a second
layer, about 0.060 inches thick of hybrid resin and filler, and a
third layer, also about {fraction (3/16)} inches thick of 8 pound
structural closed cell, hybrid resin foam, which also may contain
filler.
CHEMISTRY OF THE STRUCTURAL PANELS
[0113] As noted above, the high density thermosetting hybrid resin
of tile present invention which may also be referred to as high
density polyurethane and polyurea or hybrid resin, is prepared by
combining components A and B with various additives to enhance the
properties of the resulting panel in accordance with the present
invention.
[0114] Components A and B that can be used for the present
invention are available from Burtin Corporation of Santa Ana,
Calif. One composition that is particularly useful for the present
invention is known by the trademark SUPERFLEX, a plural component
thermoset polyhybrid resin system. SUPERFLEX is a trademark of
Burtin Corporation. Another composition useful is a hybrid resin
made by Hehr International Polymers called TR90.
[0115] When using components A and B of the SUPERFLEX system, both
components must be preheated to a temperature of approximately
120.degree. to 140.degree. F. Appropriate heaters must be provided
in the containers and along the feed lines of 71 and 73 of the
apparatus of FIG. 14.
[0116] For SUPERFLEX, hybrid resin component A is a
pre-polymerized, monomeric diisocyanate (MDI). Component B is a
blend of polyols and catalysts (amine). Neither A nor B contains
volatile organic compounds (VOCs). They are supplied under pressure
in equal amounts to the spray head.
[0117] Reaction takes place immediately, with gel times of 3-10
seconds and tack-free times of 30-60 seconds. The reacted product
can be handled within minutes, although care must be taken to
prevent product deformation in the first few minutes. As with most
polyhybrid resins, complete polymerization does not occur for 24
hours although the product can be trimmed and finished sooner.
[0118] The hybrid resin product has good thermal stability up to
180.degree. F. It is paintable and machinable with most
conventional processes.
[0119] Although different catalysts can be used, the amount of
catalysts is selected to be between 0.1 and to 1.0 percent by
weight of the combined hybrid resin (components A plus B) and is
preferably reduced so that the curing rate, rather than being on
the order of seconds, can be increased to a minute or more to allow
for application of subsequent layers behind the first layer.
[0120] The other components, such as the sun blocker, pigment and
plasticizer are all blended with component A to avoid upsetting the
delicate catalytic action in component B. The fire retardant,
preferably bromine, in the proportion of 1.5 to 3 percent by
weight, is also present in component A. The sun blocker Tinvnin
(pronounced tin a vin) can also be used and can be in component B
(the polyol side) in the rage of 0.05% to 10% of component B,
depending on the life cycle needed for the panel. For a panel life
of 10 to 15 years, 2.5 to 7% by weight Tinvnin on thicker panels is
used to block UV passage into the panel body.
[0121] The resins used with the present invention are selected to
have a grade that produces either a "water clear" resin for the
outer, preferably thin coating, since the water clear hybrid resin
is more expensive than a more yellowish or tan lower grade hybrid
resin which is a distinctive color, but is far less expensive. The
lower grade resin is used for the rearward invisible layers where
the outer visible surface must be either clear or reveal the
underlying graphics, pigments, embedded indicia, or the like lower
layer. Structural elements that were present are also encased in
the lower grade hybrid resin. Another way to understand the
difference between the water clear, versus natural color hybrid
resin, is to appreciate the MDI and the Clear Polyol are highly
refined and very pure. They are very expensive and are the highest
priced MDI and Polyol on the market. The natural colored MDI and
Polyol are pure, but they are not refined as much to the same
extent and are, thus, much cheaper. For example, clear Iso and
clear Polyol cost approximately $5.00 to $6.00 per pound. The
natural color Iso and Polyol cost approximately $1.00 to $2.85 per
pound. Both can be used in the present invention, depending upon
the desired result. If a translucent color is required, this can be
based on clear resin containing pigments. For building panels, the
less expensive natural resin can be used with a stronger pigment
than used in the resin to produce the desired color.
[0122] The UVX.TM. product is an example of the water clear grade
hybrid resin. An example of the yellowish, less expensive, hybrid
resin is the SE-270.TM. polyurea resin product which uses the same
iso component A and polyol component B supplied in spray equipment
at a pressure of at least 1,500 PSI and maintained at a temperature
of 120-140.degree. F.
[0123] The flame retarder (bromine) is typically 1% by weight;
usually in the A side as the iso seems to carry it well. For the
invention this amount has been adjusted to 2% and 3% based on
application. For most panels 2% is used. The plasticizer in the
polyol 13 side can also range from a low of 2% to a high of 20%
based on the desired hardness of the finished panel. Examples of
usable plasticizers are phthalate, adipate and sebacate esters,
ethylene glycol, tricresyl phosphate and castor oil.
[0124] The following is a typical composition for layers of the
resin of the present invention:
EXAMPLE 1 (A RIGID URETHANE TWO-PART SYSTEM)
[0125]
2 Amount Range Ingredient Chemical (Weight %) (Weight %)
Polyisocyanate Polymeric 44 20-65 Diaphenylmethane Diisocyanate
(MDI) Plastisizer Ethylene Glycol 2.0 0.10-25 UV blocker Tinvnin
1.0 0.1-10.0 Flame retardant Bromine 1.0 0.1-10.0 Pigment Urethane
1.0 0.1-5.0 Polyol Polyester and 47 20-65 Polyether blend Catalyst
Amine 4 0.10-20
EXAMPLE 2 (A FLEXIBLE URETHANE TWO-PART SYSTEM)
[0126]
3 Amount Range Ingredient Chemical (Weight %) (Weight %)
Polyisocyanate MDI 41 20-65 Plastisizer Ethylene Glycol 5.0 0.10-25
UV Blocker Tinvnin 2.0 0.10-10.0 Flame Retardant Bromine 1.5
0.10-10.0 Pigment Urethane 0.5 0.10-5.0 Polyol Polyester and 48
20-65 Polyether blend Catalyst Amine 2.0 0.10-20
[0127] Chemistry of Available Products
[0128] The above table shows the basic chemical makeup of the
present invention. For years architects and specification writers
have looked at plastic and polymer panel products with caution.
They wanted a lightweight product with superior weatherability,
with the same fire and mechanical properties as a stone or cement
product. The present invention addresses many of the concerns and
desires of the building and automotive industries. The present
invention is based on multiple layers of resins, clear or
pigmented, on the outside or first surface. These resins are
commercially available from a variety of sources. Burtin
Corporation of Santa Ana, Calif. markets one product, a clear
topcoat, under the trade name UVX. Another product is called DUC
2021, produced by PPG Industries. Still another coating called
Chromacoat, by Dupont is available. These products can be used
successfully in the present invention based on the end use of the
product. The second layer chemistry is also very versatile.
Pigmented resin is available from many sources. The UVX clear from
Burtin can be pigmented and applied behind the first layer. Other
Products that can be used are Ultrachrome by Futura Coating of St.
Louis, Mo. Centari by Dupont and Duranar by PPG Industries may also
be used. The Duranar is very useful in the present invention as it
contains polyvinylidene fluoride (PVDF) resin. PVDF has been used
successfully for over 25 years and is a proven UV blocker.
[0129] The third and subsequent layers are also based on urethane
and polymer chemistry. Hybrid resin has been referred to throughout
the description of the present invention. Products such as Burtin's
SE271 are based on structural urethane and their SE270 is based on
polyurea chemistry. The hybrid resin is made by combining urethane
and polyurea resins in a combination that achieves the desired
mechanical and thermal chemistry. One such hybrid resin is
available from Hehr of Decatur, Ga., called HPTR90. The hybrid
resin has proven to be very useful in the present invention. Hybrid
resins can be blended to cross-link and polymerize and encapsulate
oxides found in ceramic fillers, metal traces found in and on glass
fibers, roving and matting, as well as carbon found in flyash.
[0130] Conventional thermoplastics and polymers cannot deal with
residual heat energy. Approximately 90% of the sun's heat energy is
reflected from the surface of most buildings and automotive
claddings and panels. The remaining 10% or residual energy must be
removed from the surface. The hybrid resins with oxides and carbon
containing fillers allow this residual heat energy to move into the
inner layers and into the insulating core of the product during
daylight hours and allow this same heat energy to move back to the
surface and into the air at night.
[0131] There are two primary factors that make the present
invention possible. They are 1) the ability to move residual heat
energy to achieve the desired coefficient of thermal expansion;
and, 2) improvements in the properties of plastic and polymer
products that were not previously available.
[0132] While specific embodiments of the invention have been shown
and described in detail to illustrate the application of the
principles of the invention, it will be understood that the
invention may be embodied otherwise without departing from such
principles.
* * * * *