COMPOSITE PANEL, A COMPOSITE PANEL WITH AN EDGE BAND, AND METHOD OF APPLYING AND MANUFACTURING THE SAME

Abstract

A rigid composite panel 10 for insulating an installation such as a furnace or cooler (HVAC units). The panel 10 has a thermally insulating core 20, at least two laminate assemblies 30 which are bonded to the core 20 thus forming a sandwich, and an edge band 40 adhesively applied to the edges of the sandwich 50 so as to provide a smooth, continuous, and impermeable seal around said edges. There is also claimed a method for manufacturing a rigid composite panel 10 having an edge band 40, each laminate assembly being pretreated by plasma before the edge band 40 is bonded to the panel 10. Each laminate assembly 30 consists of a thin layer of polymer 38, as well as sheets 36 bonded to the surfaces of the layer 38.

Claims

1. A method for manufacturing a rigid composite panel having an edge band, the method comprising: assembling a sandwich having edges, the sandwich consisting of a thermally insulating foam core bonded between at least two laminate assemblies, each laminate assembly comprising an insulated polymeric layer inserted between first and second sheets, each laminate assembly having an inner surface bondable to the foam core thereby forming the sandwich having peripheral exterior side edges and external corners, and an outer surface interacting with the surrounding environment, each laminate assembly providing additional thermal insulation and impact resistance; treating each laminate assembly so as to increase the adhesive properties of the edges of the sandwich by plasma treatment or corona treatment; and bonding the edge band to the to the peripheral exterior side edges of the sandwich creating a seamless, continuous and impermeable seal around the edges of the sandwich for preventing fluid and debris from entering the sandwich and contacting the foam core, wherein each external edge of each laminate assembly has an increased surface energy through the plasma treatment or the corona treatment, before the edge band is bonded to the peripheral exterior side edges of the sandwich; and wherein the edge band comprises. a substantially planar inner surface bonded to a peripheral exterior side surface of the foam core; an substantially planar outer surface opposed to the substantially planar inner surface and being generally parallel thereto; opposed first and second edge band ends, each of which joins the substantially planar inner and outer surfaces at opposite ends of the edge band, wherein the first and second edge band ends each comprise a notch, wherein the notch comprises: a first surface extending from the substantially planar inner surface toward the substantially planar outer surface and terminating therebetween; a second surface extending from termination of the first surface toward an extremity of the edge band; and the first and second surfaces defining a recess for adhesively receiving a corresponding end of the laminate assembly.

2. The method according to claim 1, wherein first surface is generally perpendicular with respect to the substantially planar inner surface and the substantially planar outer surface of the edge band.

3. The method according to claim 2, wherein the first surface is generally perpendicular with respect to the second surface.

4. The method according to claim 3, wherein the first and second edge band ends each further comprise a curved surface joining the second surface with the substantially planar outer surface.

5. The method according to claim 4, wherein each of the laminate assemblies overhangs the foam core to fit within each corresponding recess.

6. The method according to claim 1, wherein the bonding of the edge band is performed by an adhesive.

7. A method for manufacturing a rigid composite panel having an edge band, the method comprising: b) assembling a sandwich having edges, the sandwich consisting of a thermally insulating foam core bonded between at least two laminate assemblies; c) treating each laminate assembly so as to increase the adhesive properties of the edges of the sandwich; and d) bonding the edge band to the edges of the sandwich creating a seamless, continuous and impermeable seal around the edges of the sandwich.

8. The method according to claim 7, wherein the assembly of the sandwich in step a) is done by an adhesive.

9. The method according to claim 7, wherein the treatment of step b) is a plasma treatment.

10. The method according to claim 7, wherein the edge band is bonded to the edges of the sandwich in step c) by an adhesive.

11. The method according to claim 7, wherein the foam core is bonded to the inner surface of each laminate assembly by an adhesive including liquid polyurethane (PUR) glue.

12. The method according to claim 11, wherein the edge band is mounted to the edges of the sandwich by PUR glue.

13. The method according to claim 7, wherein the inner and outer surfaces are coated with a coating selected from the group consisting of PVDF and PE.

14. The method according to claim 7, wherein the edge band is a tape made from a material selected from the group consisting of rigid or flexible PVC, ABS, TPE, polyethylene.

15. The panel according to claim 7, wherein the foam core has a thickness of about 0.625-4 inches and each sheet of each laminate assembly has a thickness of about 0.1-0.6 mm.

16. A rigid composite panel for mounting onto an installation and thermally insulating the installation from a surrounding environment, the panel comprising: a thermally insulating foam core; at least two laminate assemblies, each laminate assembly having an inner surface bondable to the foam core thereby forming a sandwich having edges, and an outer surface interacting with the surrounding environment, each laminate assembly providing additional thermal insulation and impact resistance; and an edge band seamlessly mountable to the edges of the sandwich for preventing fluid and debris from entering the sandwich and contacting the foam core; wherein each laminate assembly is treated before the edge band is mounted to the edges of the sandwich so as to increase an overall adhesive strength between the edges of the sandwich and the edge band and so as to allow for a smooth, continuous and impermeable seal around the edges of the sandwich.

17. The panel according to claim 16, wherein each laminate assembly comprises a polymeric layer inserted between, and bonded to, two laminated sheets.

18. The panel according to claim 17, wherein the polymeric layer is made from a material selected from the group consisting of low-density polyethylene (LDPE), fire-retardant mineral, polypropylene, and polyethylene terephthalate (PET).

19. The panel according to claim 17, wherein the polymeric layer is bonded to two laminated sheets by an adhesive.

20. The panel according to claim 16, further comprising an additional foam core bonded to an outer surface of either one of the at least two laminate assemblies, and an additional laminate assembly bonded to the additional foam core, thereby creating a composite panel having at least two levels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] These and other objects and advantages of the invention will become apparent upon reading the detailed description and upon referring to the drawings in which:

[0025] FIGS. 1 and 2 are views of prior art composite panels equipped with an edge or “clip” band.

[0026] FIG. 3 is a perspective view of a rigid composite panel according to the present invention.

[0027] FIG. 4 is an exploded perspective view of the composite panel shown in FIG. 3.

[0028] FIG. 5 is a cut-away view of the composite panel shown in FIG. 3.

[0029] FIG. 6 is a perspective view of a laminate assembly, according to a preferred embodiment of the present invention.

[0030] FIG. 7 is a partial cut-away view along a line VII-VII of the laminate assembly shown in FIG. 6.

[0031] FIG. 8 is a perspective view of a foam core, according to a preferred embodiment of the present invention.

[0032] FIG. 9 is a perspective view of an edge band, according to a preferred embodiment of the present invention.

[0033] FIG. 10 is a cut-away view of support edge bands for structurally supporting a laminate assembly, according to a preferred embodiment of the present invention.

[0034] FIG. 10A is a close-up view a corner of the support edge bands shown in FIG. 10.

[0035] FIG. 11 is a cut-away view of a sheet or laminate assembly dividing a foam core, according to a preferred embodiment of the present invention.

[0036] FIG. 12 is a cut-away view of a two-step composite panel, according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0037] According to the present invention, and as shown in FIGS. 3 to 4, the rigid composite panel 10 is composed of a thermally insulating foam core 20, at least two laminate assemblies 30, and an edge band 40.

[0038] Referring to FIG. 4, the laminate assemblies 30 are bonded, preferably by an adhesive, to the foam core 20. The inner surfaces 32 of the laminate assemblies 30 receive an adhesive which allows them to be bonded or attached to the horizontal surfaces (in the sense shown in FIG. 4) of the foam core 20. The bonding of the laminate assemblies 30 to the foam core 20 creates a sandwich 50 with edges. The edge band 40 (shown in an exploded configuration) is then bonded to these edges, preferably by using an adhesive.

[0039] FIG. 5 provides a cross-sectional view of the panel 10 when fully assembled and shows the relationship between the foam core 20, the laminate assemblies 30 and the edge band 40. Thus, the rigid composite panel 10 of the present invention is formed and ready to be used for insulating purposes.

[0040] Turning now to the components and features of the panel 10, particularly the laminate assemblies 30, FIGS. 6 and 7 illustrate a preferred embodiment of the laminate assemblies 30. Each laminate assembly 30 has an inner and outer surfaces 32,34. The inner surface 32 is bonded to the foam core 20, again preferably by adhesive, although other techniques such as mechanical fasteners, for example, can be used. The outer surface 34 is exposed to the surrounding environment of the composite panel 10. The inner and outer surfaces 32, 34 are also preferably coated so as to provide insulation, fire retardation, electrical resistance, corrosion resistance etc. properties to the laminate assembly 30. These coatings can be PVDF or PE.

[0041] Each laminate assembly 30 preferably also has at least two laminated sheets 36 which are each preferably made of plastic, aluminum, stainless steel, PVC, ABS, or other similar materials known in the art. The material of the sheets 36 allows them to resist indentations, nicks, scratches, or bumps, thus preserving the properties of the laminate assembly 30, as explained in more detail below. The sheets preferably have a thickness of about 0.0118 inches, but this thickness can vary depending on the material used for their fabrication and the requirements of the installation, as apparent to a person skilled in the art. The laminate assembly 30 also preferably comprises a polymeric layer 38, which is inserted between the two sheets 36 and bonded thereto, preferably by an adhesive. The layer 38 is preferably made of any insulating polymer, such as low-density polyethylene (LDPE), fire-retardant mineral, and any other such insulating materials known in the art.

[0042] Turning now to FIG. 8, the foam core 20 is the principal thermal insulator of the composite panel 10. The length and width of the core 20 can be varied so as to match the dimensions of the laminate assemblies 30. The foam core 20 is preferably rigid foam so as to reinforce the structural rigidity to the panel 10. Preferably, the thickness of the core 20 is about 1.75 inches, but this thickness can vary depending on the material used for the core 20 and the installation requirements, as apparent to a person skilled in the art. The core 20 is preferably bonded to the inner surfaces 32 of the laminate assemblies 30 by any suitable adhesive known in the art. Preferably, the core 20 is made from an insulating polymer such as EPS (STD, NEOPOR), polyisocyanurate, etc. known in the art.

[0043] FIG. 9 illustrates the edge band 40 according to a preferred embodiment of the present invention. The edge band 40 provides a seamless, smooth, and continuous seal between the edges of the sandwich 50 formed by the laminate assemblies 30 and the foam core 20, thereby preventing the ingress and/or accumulation of moisture and/or debris. The edge band 40 is bonded to the edges of the sandwich 50 by any suitable adhesive known in the art. The edge band 40 can be one continuous piece, such as a tape, which is bonded by rolling out the tape and applying it to the edges of the sandwich 50. In another preferred embodiment, the edge band 40 can be discrete pieces or strips, as illustrated in FIG. 4, which are each bonded separately to a an edge of the sandwich 50. It should be noted that even if the edge band 40 consists of discrete strips, the strips would be bonded to the sandwich and to each other so as to provide a seamless, smooth and continuous seal. Preferably, the edge band 40 is made from rigid or flexible PVC, ABS, TPE, polyethylene and/or any other suitable material known in the art. The edge band 40 is able to be bonded seamlessly because the band 40 is tangentially assembled with adhesive to the exterior surfaces of the laminate assemblies 30 and foam core 20 (i.e. the edges of the sandwich 50).

[0044] In a preferred embodiment illustrated in FIG. 10, the edge band 40 provides structural support and reinforcement to the panel 10, as explained hereinbelow. In this embodiment, the edge band 40 has notches 42 at each end 44 of the edge band 40. The notches 42 are designed, configured and manufactured to receive a corresponding end 39 of the laminate assembly 30. When the end 39 is adhesively received in the notch 42, the laminate assembly 30 is constrained in its motion relative to the edge band 40, as illustrated in FIG. 10.

[0045] Preferably, and as illustrated in FIG. 11, the panel 10 can include an additional laminate assembly 30 and/or sheet 36 which is inserted into the panel 10 so as to divide its thickness (and the foam core 20) by a certain amount, i.e. in half for example. In another preferential embodiment, the panel 10 can be a “double” panel 10, meaning that an additional foam core 20 can be bonded to either one of the outer surfaces 34 of the laminate assemblies 30. Once so bonded, an additional laminate assembly 30 can be bonded to the non-bonded surface of the additional foam core 20, thus forming a double-layered panel. Of course, numerous variants on this design are possible, as apparent to a person skilled in the art. For example, the panel 10 can be made “triple”, “quadruple”, or any multiple according to this preferred embodiment depending on the insulation requirements and the installation size constraints. The panel 10 can also comprise alternating layers of foam core 20, laminate assemblies 30, or can be “stacked” meaning that the panels 10 are stacked together. In another preferred embodiment, the panel 10 can have a non-quadrilateral profile such as, but not limited to, a triangle, a circle, an ellipse, and any other shape or size that would be suitable for a given installation.

[0046] The panel 10 according to the present invention can be any three-dimensional shape and is not limited to parallelepipeds. For example, and as illustrated in FIG. 12, the panel 10 can have a “step” configuration wherein both laminate assemblies 30 are not of equal dimension. Similarly, the edge bands 40 can have a “z” or “s” configuration so as to match the dimensions of the laminate assemblies 30, and depending on the installation's requirements, as apparent to a person skilled in the art. Of course, numerous other shapes, configurations and/or geometries are possible.

[0047] There is also provided a method for manufacturing a rigid composite panel 10 having an edge band 40. The method has the steps of assembling the sandwich 50 with edges, as described in more detail above. Then, each laminate assembly 30 is treated so as to increase its adhesive properties, and the edge band 40 is finally bonded to the edges of the sandwich 50 so as to create the seamless, continuous and impermeable seal which is described above. When treating each laminate assembly 30, the polymeric layer 38 is preferably treated along its exposed edges. It is understood that each laminate assembly 30 can be treated before or after the assembly of the sandwich 50. In fact, each laminate assembly 30 can be treated at any time before the edge band 40 is bonded to the edges of the sandwich 50.

[0048] The above-mentioned treatment in the context of the invention is preferably plasma treatment, but can also be corona treatment. It is understood in the art that plasma treatment has the effect of activating the surface of numerous types of materials such as plastics, metals and glass. By activating the surface of these materials, the surface energy of a surface which is to be bonded is increased. The higher the surface energy, the better the subsequent adhesion the surface will have to another material, such as a plastic. Thus, a stronger adhesive bond between the edges of the polymeric layer 38 and the edge band 40, as well as between the edges of the sandwich 50 and the edge band 40, is obtained by increasing the surface energy of the polymeric layer 38 via plasma treatment prior to the edge band 40 being adhesively bonded to the edges.

[0049] Furthermore, the present invention is a substantial improvement over the prior art in that, by virtue of its design and components, the rigid composite panel 10 with an edge band 40 is seamless, has a higher surface energy, is lightweight, easy to install, and offers unique thermal insulating properties when compared to the panels known in the art. Hence, it may now be appreciated that the present invention represents important unforeseeable advantages over other panels known in the prior art, in that the panel 10 according to the present invention prevents the ingress and/or accumulation of fluids and/or debris because of the continuous seal of the sandwich 50 provided by the edge band 40. Thus, the insulation properties are better preserved and enhanced because no foreign matter that may negatively affect the insulating qualities of the panel 10 is introduced into the panel 10. The seamless seal also provides a further unexpected advantage in that the growth of mildew and/or mold is greatly prohibited and even eliminated for most installations.

[0050] Indeed, contrary to panel shown in FIGS. 1 and 2, the edge band 40 according to the present invention forms a seamless seal with the sandwich 50 of the panel 10, and this, without the use of mechanical fasteners in a preferred embodiment, which advantageously reduces manufacturing costs and manufacturing times. More specifically, the seamless edge band 40 leaves no gap between the band 40 and the foam core 20 into which moisture and/or debris may ingress and/or accumulate. In a preferred embodiment, the edge band 40 beneficially provides structural support to the panel 10 by employing notches 42, which support and retain the ends 39 of the laminate assemblies 30.

[0051] Yet another advantage of the panel 10 according to the present invention is that the coating on the inner and outer surfaces 32,34 of the laminate assemblies 30 further enhances the desired properties of the panel 10 such as high thermal insulation efficiency, resistance to corrosion, and fire retardation and/or resistance.

[0052] The panel 10 according to the present invention is also more rigid than panels known in the art. This rigidity and resistance to impact forces is derived from the material of the sheets 36, the structure of the foam core 20, and also from the reinforcement that results from having multiple layers of laminate assembly 30 and foam core 20. Further rigidity is achieved by adhesively sealing all the components of the panel 10. This rigidity and resistance to impacts and indentations is important because, as it is well understood in the art, when composite panels have indentations or scratches, the panels are less effective because the scratches can remove beneficial coatings on the outer surfaces of the panels, and the indentations can create a thermal bridge between the two sheets of the panel, thus allowing energy to bypass the insulating foam core and reducing the insulation efficiency of the panel.

[0053] Of course, the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. Numerous modifications could be made to the above-described embodiments without departing from the scope of the claims, as apparent to a person skilled in the art. Furthermore, it is apparent that this invention can apply to many other uses.