Abstract: Implementations of the present invention relate to systems, methods, and apparatus for manufacturing aesthetically pleasing, decorative architectural resin panels having high-resolution image layers. In particular, at least one implementation includes a laminated resin panel having a decorative image layer formed from layered or cross-linked ink free from cracks, splits, or other deformation. Additional implementations relate to curved or otherwise non-planar decorative architectural resin panels having high-resolution image layers.

Abstract: Implementations of the present invention relate to for incorporating virgin or recycled thermoplastic resin materials into architectural thermoplastic panels that have ordered and reproducible geometric patterns. More specifically, at least one implementation provides a method for fusing thermoplastic elongated members, such as circular rods and rectangular bars, sourced from recycled thermoplastic resin to form the architectural thermoplastic panels.

Abstract: Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

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: 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: 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 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: Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

Abstract: Implementations of the present invention relate generally to methods, systems, and apparatus for manufacturing aesthetically pleasing, resin-based sheets including color and/or multi-decorated images. In particular, at least one implementation includes subjecting at least one surface of a polymer sheet to uniform heat and pressure in order to sublimate a dye into the surface, and ensure that that polymer sheet is not warped or otherwise damaged during processing. Additional implementations include decorative architectural resin panels including a resin sheet having a dye sublimated into one or more surfaces in order to create an effect of depth or other aesthetic.

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: Implementations of the present invention relate generally to methods, systems, and apparatus for manufacturing aesthetically pleasing, resin-based sheets including color and/or multi-decorated images. In particular, at least one implementation includes subjecting at least one surface of a polymer sheet to uniform heat and pressure in order to sublimate a dye into the surface, and ensure that that polymer sheet is not warped or otherwise damaged during processing. Additional implementations include decorative architectural resin panels including a resin sheet having a dye sublimated into one or more surfaces in order to create an effect of depth or other aesthetic.

Abstract: Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

Abstract: Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

Abstract: Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

Abstract: Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

Abstract: A dichroic, light refracting resin panel comprises one or more dichroic/refracting films that have been embedded and/or laminated between a plurality of resin substrates, such as copolyester, polycarbonate, and/or acrylic substrates. The dichroic resin panel can be manufactured with a variety of different materials, and with autoclave or hot press methods in a manner that ensures structural and aesthetic integrity. Specifically, a dichroic resin panel in accordance with the present invention can be created in such a way as to avoid delamination despite a variety of end-uses and formations (e.g., curved panel, embossed/textured surfaces). In addition, the dichroic resin panels can be handled, transported, and installed in a variety of exterior or interior applications, even where certain building code requirements may be relatively stringent. The dichroic resin panels can be used in a variety of structural and/or aesthetic applications.