Abstract: A method for manufacturing the biopolymer panel may include positioning a plurality of biopolymer sheets adjacent to one another, and subjecting them to a laminating temperature that exceeds the glass-transition temperature of the sheets for a time period sufficient to achieve lamination. The laminate panel is then quenched at a quenching temperature that is below the glass-transition temperature. The time period during lamination, as well as any “rest” period between lamination and quenching, is sufficiently short so as to prevent clouding or hazing as a result of crystallization of the biopolymer resin materials. In addition, the panel exhibits sufficient flame retardancy to meet applicable building codes, exhibits sufficient impact resistance for use as a decorative or structural panel building material, and exhibits no substantial thermally induced degradation as a result of subjection to the laminating temperature. The panels may be used as decorative or structural building materials.

Abstract: Implementations of the present invention relate to systems, methods, and apparatus for applying heat and pressure to a laminate assembly and to form a unitary product therefrom with increased processing efficiency. One implementation includes an apparatus that can decrease processing time by directly heating and cooling platens that press the laminate assembly. Additionally, the lamination press can allow the platens to flex about the laminate assembly, thereby applying substantially uniform pressure to the laminate assembly.

Abstract: An architectural panel comprises a structured core embedded in a resin material such that the resin material fills the cells of the structured core. In at least one implementation, a method of making the panel comprises pressing two or more resin substrates about the structured core at a pressure and temperature such that the resin substrates flow into and fill the cells of the structured core. In at least one other implementation, a method of making the panel comprises placing the structured core into a form, pouring a liquid resin material into the form, and allowing the resin material to harden.

Abstract: A structured-core laminate panel can be made in an efficient, structurally sound manner without the use of adhesives (film or liquid forms) using materials with different melt or glass transition temperatures. In one implementation, a manufacturer positions one or more resin substrates about a structured core, which comprises a relatively high melt or glass transition temperature compared with that of the one or more resin substrates. The manufacturer heats the assembly to at least the glass transition temperature of the resin substrates, but not to the melt or glass transition temperature of the structured core. This allows the one or more resin substrates to melt and bond (mechanically, chemically, or both) to the structured core on one side (or inner surface), while maintaining a substantially planar or original conformation on an opposing side (or outer surface).

Abstract: Implementations of the present invention relate to decorative thermoplastic resin panels, which can include one or more recesses. The recess of the thermoplastic resin panels can have texture or texture patterns that differ from the texture or texture patterns of non-recessed portions or other recesses of the decorative thermoplastic resin panel. Additionally, the present invention relates to a method for forming recesses in thermoplastic panels with a flexible die.

Abstract: A structured-core laminate panel can be made in an efficient, structurally sound manner without the use of adhesives (film or liquid forms) using materials with different melt or glass transition temperatures. In one implementation, a manufacturer positions one or more resin substrates about a structured core, which comprises a relatively high melt or glass transition temperature compared with that of the one or more resin substrates. The manufacturer heats the assembly to at least the glass transition temperature of the resin substrates, but not to the melt or glass transition temperature of the structured core. This allows the one or more resin substrates to melt and bond (mechanically, chemically, or both) to the structured core on one side (or inner surface), while maintaining a substantially planar or original conformation on an opposing side (or outer surface).

Abstract: A method of making a photovoltaic panel includes previously preparing one or more pre-formed substrates with a first temperature and pressure to be non-planar, textured, embossed, colored, or combinations thereof. A manufacturer can then prepare a laminate assembly comprising one or more organic photovoltaic components one or more pre-formed substrates, and a barrier layer with one or more thermally-activated thermoplastic tie layers there between. The manufacturer can then finish the photovoltaic panel lamination by subjecting the assembly to a second set of temperatures and pressures sufficient to activate and bond the pre-formed substrate, barrier layer, and photovoltaic components without significantly softening the pre-formed substrates or otherwise degrading/damaging the organic photovoltaic components. A non-planar panel made by this method can be used in both exterior and interior decorative and/or structural applications where electrical generation is desired.

Abstract: In general, implementations of the present invention include devices, systems, and components for mounting and/or displaying panels and panel structures with one or more post modules. The post modules, according to the present invention, can include a post, which can secure one or more panels, and covers that can conceal the post from view. Additionally, the post modules can have hollow channels between the covers and the post, which can house wires, cords, lighting elements, and other components.

Abstract: Implementations of the present invention relate to devices, systems, and methods related to mounting decorative slats. In particular, the present invention facilitates accurate mounting and installation of a decorative multi-slat system, which can provide aesthetic enhancement for a particular space. Furthermore, the method of installing the decorative multi-slat system can allow an installer to reduce likelihood of errors and misalignments of the system, which can occur during the installation.

Abstract: A variable interlayer laminate panel can include resin material derived from other resin panels, enabling use of waste trimmings from the manufacture of the other resin panels. Implementations therefore enable manufacturers to produce high-fashion but waste conscious resin panels that have a high degree of recycled content. In one implementation, a manufacturer forms a laminate panel by positioning a plurality of independent resin portions over a first resin substrate, and then by positioning a second resin substrate over the resin portions. The resin portions comprise embedded decorative elements, and at least two different resin portions comprise different types of decorative elements. The manufacturer then forms the laminate panel through the application of pressure and heat. The resulting panel has a variable interlayer formed from the independent resin portions. The laminate panel is usable as part of a panel system.

Abstract: Implementations of the present invention comprise lighting fixture assemblies that minimize the visibility of hardware and shadows. In particular, the lighting fixture assemblies may include no supporting hardware extending through an internal space defined, in whole or in part, by the lighting fixture assembly. In addition, the lighting fixture assemblies may include a gap between a bottom/top panel and a side panel of the lighting fixture assembly. Accordingly, lighting fixture assemblies of one or more implementations of the present invention can reduce or eliminate the visibility of internal supporting hardware and shadows on the exterior surfaces of the lighting fixture assemblies.