Protective panel and method of manufacture and use

Abstract

The present invention is directed to an apparatus and system involving the use of a panel for protecting fenestrations in buildings such as windows and doors, from damage caused by storms, tornadoes, hurricanes, riots, and the like. Embodiments of the present invention include a substrate panel attached to a security film providing increased protection against wind-driven missiles associated with high winds with decreased weight and mitigating improper installation.

Claims

1. A protective panel comprising: a first translucent substrate panel comprising a fluted polypropylene construction, the substrate panel having a first side and a second side; a first security film having a first side attached to the first side of the substrate panel by a first adhesive layer disposed therebetween, wherein the first security film comprises one of polyester or polyethylene terephthalate; a cutting guide visible from the first side of the substrate panel; wherein the protective panel is configured to be affixed over one of a door or window of a building structure with the second side of the substrate panel toward the building structure.

2. The protective panel of claim 1, further comprising a border visible from the external aspect of the protective panel having a width extending from extents of the protective panel, wherein the border indicates an area inset from the extents of the protective panel in which fasteners should not be placed.

3. The protective panel of claim 1, further comprising a reinforced area adjacent to extents of the protective panel.

4. The protective panel of claim 1, further comprising printed matter visible from an external aspect of the protective panel, wherein the printed matter comprises at least one of installation instructions or code compliance information.

5. The protective panel of claim 1, further comprising integrated lighting.

6. The protective panel of claim 5, wherein the integrated lighting comprises a luminescent compound.

7. A protective panel comprising: a first translucent substrate panel having a first side and a second side; a first security film having a first side interconnected to the second side of the first substrate panel; a second substrate panel having a first side attached to a second side of the first security film; a cutting guide visible from the first side of the first substrate panel; wherein the protective panel is configured to be affixed to a structure with the second side of the second substrate panel toward the structure.

8. The protective panel of claim 7, wherein the substrate panels and the first security film have adhesive layers disposed therebetween.

9. The protective panel of claim 7, further comprising a border visible from the external aspect of the protective panel having a width extending from extents of the protective panel, wherein the border indicates an area of the protective panel in which fasteners should not be placed.

10. The protective panel of claim 7, further comprising a reinforced area adjacent to the extents of the protective panel.

11. The protective panel of claim 7, further comprising printed matter visible from an external aspect of the protective panel, wherein the printed matter comprises at least one of installation instructions or code compliance information.

12. The protective panel of claim 1, further comprising a second security film having a first side attached to the second side of the first substrate panel.

13. The protective panel of claim 12, wherein the security films and the first substrate panel have adhesive layers disposed therebetween.

14. The protective panel of claim 12, further comprising a border visible from the external aspect of the protective panel having a width extending from extents of the protective panel, wherein the border indicates an area of the protective panel in which fasteners should not be placed.

15. The protective panel of claim 14, further comprising a reinforced area adjacent to the extents of the protective panel.

16. The protective panel of claim 1, further comprising printed matter visible from an external aspect of the protective panel, wherein the printed matter comprises at least one of installation instructions or code compliance information.

17. A protective panel comprising: a translucent substrate panel comprising a fluted polypropylene construction, the substrate panel having a first side and a second side; a translucent security film having a first side and a second side, the first side of the security film interconnected to the first side of the substrate panel; a cutting guide visible from the second side of the security film; printed matter visible from the second side of the security film, wherein the printed matter comprises at least one of installation instructions of the protective panel or code requirements met by the protective panel; and a border extending about 2.54 cm (1 in.) inward from the extents of the protective panel, wherein the protective panel is configured to be affixed to a structure by fasteners disposed through the panel and into the structure, and wherein the fasteners do not perforate the border, with the second side of the substrate panel facing toward the structure.

18. The protective panel of claim 7, wherein the first and second substrate panels comprise a fluted polypropylene construction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1—A cross-sectional side-view of certain embodiments comprising a protective panel

(2) FIG. 2A—A cross-sectional side-view of certain embodiments comprising a protective panel

(3) FIG. 2B—A cross-sectional side-view of certain embodiments comprising a protective panel

(4) FIG. 2C—A cross-sectional side-view of certain embodiments comprising a protective panel

(5) FIG. 3A—A front view of certain embodiments of a protective panel

(6) FIG. 3B—A side cross-sectional view of certain embodiments of a protective panel having fasteners disposed therethrough

(7) FIG. 4A—A front view of certain embodiments comprising a protective panel having a cutting guide

(8) FIG. 4B—A front view of certain embodiments comprising a protective panel having a cutting guide

(9) FIG. 5—A front view of certain embodiments comprising a protective panel affixed to a structure

(10) FIG. 6—A side cross-sectional view of certain embodiments of a protective panel having fasteners disposed through a reinforced area

(11) FIG. 7—A front view of certain embodiments comprising a protective panel having printed matter

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

(12) Certain embodiments of the present invention, such as shown in FIG. 1, comprise protective panel 1000 comprising a substrate panel 1010 having a security film 1020 attached thereto, wherein a first side 1021 of the security film is attached to the first side 1011 of the substrate panel.

(13) In certain embodiments, such as shown in FIG. 1, the substrate panel 1010 has a thickness 1030 and comprises a first side 1011, a second side 1012 parallel to the first side, and fluted construction therebetween. The fluted construction of such panels is typically characterized by intermediate walls 1040 which are perpendicular to the first side 1011. The walls 1040 of such an embodiments typically results in a rectilinear array of flutes 1050. Certain embodiments comprise a substrate panel which is extruded during a manufacturing process, however alternative embodiments employ alternative manufacturing methods while keeping with the spirit and scope of the present invention. Although flutes having a rectangular profile are disclosed, a substrate panel 1010 having flute profiles varying in size or shape from those disclosed herein, such as an “O” shape, are within the spirit and scope of the present invention.

(14) In certain embodiments, the fluted construction of a substrate panel comprises a corrugated form, wherein the fluted construction is characterized by a first side, a second side parallel to the first side, and a corrugated material therebetween. It will be appreciated that a corrugated material is characterized by a series of parallel alternating ridges and furrows such as found in cardboard products.

(15) The substrate panel of certain embodiments comprises a material composition of one or more of the following materials: fluted plastic, solid plastic, wire mesh, plastic mesh, cardboard, Masonite, plywood, metal, foam, foamboard, gypsum board, high density gypsum board, sheathing substrates, wood sheets, acrylic, polycarbonate, vinyl, oriented strand board, and fabric (e.g. polyester, nylon, cotton, rayon, recycled plastic based fabric). It will be appreciated however, that alternative embodiments of the present invention comprising a substrate panel of other material composition are within the spirit and scope of the present invention.

(16) In certain embodiments, the security film of a protective panel comprises polyester, or polyethylene terephthalate (commonly referred to as PET). Certain embodiments comprise a security film comprising one or more of the following materials: acrylic, polycarbonate, polyvinyl chloride (PVC), polyethylene terephthalate glycol (PETG), phenolics, ultra-high molecular weight polyethylene (UHMW-PE), acrylonitrile butadiene styrene (ABS), polyoxymethylene (POM), polyamide-imide (PAI), polyimide (PI), and nylon. It will be appreciated however, that alternative embodiments of the present invention comprising a security films of other material composition are within the spirit and scope of the present invention. It will be further appreciated that a security film comprising a film, sheet, or panel herein referred to as “security film”, are within the spirit and scope of the present invention.

(17) In certain embodiments, as shown in FIG. 1, a first side 1001 of the protective panel is configured to face away from a structure, while a second side 1002 of the protective panel is configured to face toward a structure when affixed to the structure. In alternative embodiments it will be appreciated that the installation of a panel wherein the first side is affixed against a structure is within the spirit and scope of the present application.

(18) In certain embodiments, such as shown in FIG. 2A, the attachment of a security film 1020 to a substrate panel 1010 comprises an adhesive layer 2000 disposed between adjacent faces of the security film 1020 and the substrate panel 1010. In certain embodiments, the adhesive layer 2000 comprises a spray adhesive applied to the security film 1020 or the substrate panel 1010 prior to the attachment of the substrate panel to the security film. Certain embodiments comprise one or more of the following adhesives: vinyl acetate, polyvinyl acetate, cyanoacrylate, hot melt polymers, pressure sensitive adhesives (PSA), spray adhesives, contact adhesives, epoxy, polyurethane, or water-based adhesives. It will be appreciated however, that alternative embodiments of the present invention comprising an adhesive layer of other material compositions are within the spirit and scope of the present invention.

(19) The application of adhesives between a substrate panel in certain embodiments comprise one or more of the following methods: spray application, roll-on, brush-on, dipping, knife rolling, vacuum deposition, and powder coating. Alternatively, an adhesive comprising solid and liquid properties are held in a fluidized bed prior to application. It will be appreciated however, that alternative embodiments of the present invention comprise other methods of application of adhesive for the attachment of a security film to a substrate panel are within the spirit and scope of the present invention.

(20) Certain embodiments of a protective panel comprising a substrate panel and security film attached to each other using alternative method such as hot roll lamination or other embedding technologies known to those skilled in the art. It will be appreciated that the combination of a substrate panel with a security panel during manufacture may be desirable for purposes such as cost and time for manufacture.

(21) A protective panel 1000 of certain embodiments, such as shown in FIG. 2A, comprise a security film 1020 attached to a substrate panel 1010. Alternative embodiments, such as shown in FIG. 2B, comprise a first substrate panel 1010, a second substrate panel 1010, and a security film 1020 attached therebetween. Yet another alternative embodiments, such as shown in FIG. 2C, comprise a first security film 1020, a second security film 1020, and a substrate panel 1010 attached therebetween.

(22) Certain embodiments, as shown in FIG. 3A, comprise a border 3000 visible from an external aspect 3005 of the protective panel 1000 wherein the border 3000 is visible from a second side 3010 of the protective panel when the protective panel is affixed with a first side against a structure. The border 3000 of certain embodiments comprises a width 3020 offset from the extents 3030 of a protective panel and provides a visual cue to installers to not place fasteners within the border. It will be appreciated that a border 3000 of as discussed herein may comprise a line, an area of different color or patterning differing from the surrounding area, instructive words, or a combination thereof while being within the spirit and scope of the present invention.

(23) A protective panel of certain embodiments, as shown in FIG. 3A, comprise a border 3000 visible from an external aspect 3005 of the protective panel. The border 3000 of certain embodiments comprises a visual guide indicating an area which a user should not affix fasteners 3040 within when fastening the protective panel to a structure. Thus, the border provides a visual cue for the proper fastening of the protective panel 1000 to a structure with a minimum offset 3020 such that the fastener 3040 is not at risk of tearing through the extent 3030 or edge of the protective panel as a result of an impact event. Certain embodiments, for instance, comprise a border 3020 having a width of 7.62 cm (3 in). Thus, an installer is thereby directed to not place fasteners 3040 within 7.62 cm (3 in) of the extents of the protective panel 1000.

(24) A protective panel 1000 of certain embodiments, such as shown in FIG. 4A and FIG. 4B comprises a cutting guide 4000 visible from an external aspect 3005 of the protective panel. The cutting guide of certain embodiments, as shown in FIG. 4A, comprises orthogonally oriented lines 4010 creating a rectilinear pattern wherein the lines 4010 are equally spaced from each other. The lines 4010 of the cutting guide of certain embodiments are spaced 7.62 cm (3 in) apart. It will be appreciated that the spacing of such lines 4010—such as when indicating maximum spacing 4020 of fasteners for the attachment to a structure—is dependent upon physical properties of the protective panel, fastener diameter, and fastener offset from the extents of the protective panel. In certain embodiments, as shown in FIG. 4B, the cutting guide 4000 comprises lines 4010 indicating panel sizes for common fenestration sizes allowing an installer to cut the protective panel 1000 quickly without requiring measuring the fenestration. Thus, it will be appreciated that alternative embodiments having alternative grid line 4010 spacing (such as 2 inches or 1 inch apart) are within the spirit and scope of the present invention. In certain embodiments, the cutting guide 4000 comprises lines 4010 that are marked with the spacing units (i.e., such as 1 inch increments) allowing an installer to quickly cut the protective panel 1000 to the desired size without the need for a measuring tape or other measuring tool. In other embodiments, the cutting guide can comprise one or more common fenestration sizes such as common window size openings in the geographic area where the panels are to be sold or distributed.

(25) A protective panel 1000 of certain embodiments, as shown in FIG. 5, is fastened to a structure 5000 by means of one or more of the following fasteners 3040: screw fasteners, nails, countersunk reusable threaded holes, hook-and-loop fasteners. In certain embodiments, for instance those requiring the penetration of the protective panel with a mechanical fastener such as a screw or nail, apertures 3050 (FIG. 3) are pre-installed in the panels with a minimum offset 3020 from the extents 3030 of the protective panel, and a maximum spacing 4020 for the installation of fasteners 3040. Such apertures 3050 can be preinstalled by way of drilling, punching, hot melted, plasma cut, laser cut, or by other methods known to those skilled in the art.

(26) A protective panel of certain embodiments, shown in FIG. 1 and FIG. 2A, comprises a substrate panel 1010 having a fluted construction with a fire retardant and UV stable polypropylene material composition. The substrate panel 1010 of certain embodiments comprises a density between about 200 g/m.sup.3 and 5000 g/m.sup.3 and a thickness 1030 between 2 mm (0.078 in) and 12 mm (0.472 in). Certain embodiments comprise a security film 1020 having a thickness 1060 between about 0.025 mm (0.001 in) and 1.27 mm (0.05 in). In certain embodiments it may be desired for the thickness 1060 of the security film to be between about 0.05 mm (0.002 in) and 0.5 mm (0.02 in). The security film 1020 is attached to a first side 1011 of the substrate panel. Although certain embodiments of substrate panels and security films have been disclosed herein, it will be appreciated that embodiments comprising substrate panels or films outside the thicknesses disclosed herein are within the spirit and scope of the present invention.

(27) A protective panel of certain embodiments, as shown in FIG. 6, comprises a reinforced area 6000 adjacent to the extents 3030 of the protective panel. The reinforced area 6000 having a width 6010, is intended to further mitigate tear-through, and comprises an additional layer of material discussed herein. Accordingly, a reinforced area of 6000 embodiments comprises an additional layer of material such as those used for security film or substrate panel. In certain embodiments a reinforced area comprises a different material composition having higher tensile strength or higher shear strength than the portion of the protective panel 1000 outside the reinforced area. In certain embodiments the reinforced area overlaps a portion or entirety of a border of the protective panel.

(28) Certain embodiments comprising a protective panel, as shown in FIG. 7, comprise printed information 7000 on the protective panel 1000. The printed information 7000 of certain embodiments code compliance information, installation instructions, installation diagrams, or other instructional information pertaining to the operation or installation of the protective panel 1000. In certain embodiments (not shown), a protective panel comprises printed matter including imagery resembling a window or other imagery such wherein the installation of a protective panel resembles the structure or fenestration which it protects.

(29) A protective panel of certain embodiments comprises a color temperature of light transmission wherein light transmits through the panel is affected such that the transmitted light provides a color temperature. It will be appreciated to those skilled in the art that color temperature as related to light transmission is commonly measured on the Kelvin (K) scale wherein a color temperature below 3000K is consistent with early morning light and incandescent light. Light having a temperature below 3000K often referred to as a “warm.” Color temperatures in the 3000-4000 range are commonly referred to as “mid-range,” while those above 4000K are considered “white” which enhances the blue light spectrum, flattens the red-light spectrum. Light above 5000K is associated with mid-day sunlight and outdoor natural lighting on a sunny day. It will be appreciated warm light is associated with providing a calming effect while “white” light is associated with providing a true view of colors and has an awakening effect on those around it. It is within the spirit and scope of the present invention for certain embodiments to comprise a protective panel having warm light transmission properties, alternative embodiments to comprise a protective panel having a mid-range light transmission properties, and further alternative embodiments to comprise a protective panel having a white light transmission properties. Certain embodiments comprise a panel having light transmissive properties of over 15%. Certain embodiments comprise a light transmissive property of 25%.

(30) A protective panel of certain embodiments comprises integrated lighting wherein the panel produces light which is transmitted to at least one side of the protective panel. Integrated lighting in certain embodiments comprises integrated lights with a power source such as a battery, while alternative embodiments comprise a luminescent compound or luminescent pigment. It will be appreciated to those skilled in the art that luminescence as applied to the present invention surrounds the emission of light by a substance not resulting from applied heat. Luminescence includes but is not limited to chemiluminescence, bioluminescence, electroluminescence, and photoluminescence.

(31) While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention. Further, the inventions described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “adding” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items.