Panel system having shaped fold

Abstract

The present invention is directed to a panel system and manufacturing method in which a shaping member is used to form and support a similarly shaped fold in a panel. The shaping member can be held in position against the fold using one or more stiffening members.

What is claimed is:  
     
         1 . A panel system for engagement with a structural member, comprising: 
 at least one panel having a radiused fold wherein the radius is less than fifteen times the thickness of the panel; and    a radiused shaping member contacting the interior surface of the fold and extending at least a substantial length of the fold.    
     
     
         2 . The panel system of  claim 1 , wherein the shaping member has a circular shape.  
     
     
         3 . The panel system of  claim 1 , wherein the shaping member has an elliptical shape.  
     
     
         4 . The panel system of  claim 1 , wherein the shaping member has a parabolical shape.  
     
     
         5 . The panel system of  claim 1 , further comprising a plurality of stiffener supports spaced at intervals along the length of and contacting the shaping member.  
     
     
         6 . The panel system of  claim 3 , further comprising one or more perimeter extrusions engaging one or more peripheral edges of the at least one panel.  
     
     
         7 . The panel system of  claim 4 , wherein the plurality of stiffener supports each contact a perimeter extrusion.  
     
     
         8 . The panel system of  claim 5 , wherein the plurality of stiffener supports contact a common perimeter extrusion at distal ends of the supports and wherein proximal ends of the supports contact the shaping member.  
     
     
         9 . The panel system of  claim 1 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         10 . The panel system of  claim 2 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         11 . The panel system of  claim 3 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         12 . The panel system of  claim 4 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         13 . The panel system of  claim 5 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         14 . The panel system of  claim 6 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         15 . The panel system of  claim 1 , wherein the radius of the radiused fold is no more than about ten times the thickness of the panel.  
     
     
         16 . The panel system of  claim 2 , wherein the panel is metal.  
     
     
         17 . The panel system of  claim 3 , wherein the panel is metal.  
     
     
         18 . The panel system of  claim 4 , wherein the panel is metal.  
     
     
         19 . The panel system of  claim 5 , wherein the panel is metal.  
     
     
         20 . The panel system of  claim 6 , wherein the panel is metal.  
     
     
         21 . A panel system for engagement with a structural member, comprising: 
 at least one panel having a shaped fold;    at least one perimeter extrusion engaging at least one peripheral edge of the at least one panel;    a shaping member contacting the interior surface of the fold, extending a substantial length of the fold, and having at least substantially the same shape as the fold; and    a plurality of stiffening members engaging the shaping member on a proximal end and a perimeter extrusion on a distal end to hold the shaping member in position against the interior surface.    
     
     
         22 . The panel system of  claim 21 , wherein the shaping member has one of a circular, elliptical, parabolical, triangular, quadrilateral, and polygonal shape.  
     
     
         23 . The panel system of  claim 21 , wherein the panel has a plastic layer sandwiched between opposing metal layers and wherein one or the metal layers is at least partially removed adjacent to the shaping member.  
     
     
         24 . The panel system of  claim 22 , wherein the panel has a plastic layer sandwiched between opposing metal layers and wherein one or the metal layers is at least partially removed adjacent to the shaping member.  
     
     
         25 . The panel system of  claim 21 , wherein a plurality of perimeter extrusions engage the peripheral edges of the panel.  
     
     
         26 . The panel system of  claim 22 , wherein a plurality of perimeter extrusions engage the peripheral edges of the panel.  
     
     
         27 . The panel system of  claim 23 , wherein a plurality of perimeter extrusions engage the peripheral edges of the panel.  
     
     
         28 . The panel system of  claim 21 , wherein the plurality of stiffener supports contact a common perimeter extrusion.  
     
     
         29 . The panel system of  claim 21 , wherein the proximal ends of the plurality of stiffener supports have at least substantially the same shape as the shaping member.  
     
     
         30 . The panel system of  claim 21 , wherein the panel has at least one metal layer and at least one plastic layer.  
     
     
         31 . The panel system of  claim 9 , wherein the panel is metal.  
     
     
         32 . A jig for manufacturing a panel assembly, comprising: 
 first and second substantially planar surfaces and    a radiused corner located between and in contact with the first and second substantially planar surfaces.    
     
     
         33 . The jig of  claim 32 , wherein the first and second substantially planar surfaces form an acute angle therebetween.  
     
     
         34 . The jig of  claim 32 , further comprising one or more plungers located at or near a peripheral edge of the first and/or second substantially planar surfaces to advance a panel towards the radiused corner.  
     
     
         35 . A method for manufacturing a panel assembly, comprising the steps of: 
 removing a portion of a surface of a panel;    engaging at least one radiused shaping member with the removed portion of the surface of the panel; and    folding the panel about the at least one shaping member to form a radiused fold having at least substantially the same shape as at least a portion of the shaping member.    
     
     
         36 . The method of  claim 35 , further comprising after the folding step: 
 placing at least one stiffening member adjacent to the panel surface and in contact with the at least one shaping member to hold the at least one shaping member in position.    
     
     
         37 . The method of  claim 35 , further comprising before the folding step: 
 engaging one or more perimeter extrusions with one or more edges of the panel.    
     
     
         38 . The method of  claim 35 , wherein at least one proximal end of the at least one stiffening member contacts the shaping member and at least one distal end of the at least one shaping member contacts a perimeter extrusion.  
     
     
         39 . The method of  claim 38 , wherein the at least one stiffening member has at least one second distal end in addition to the at least distal end and the at least one second distal end contacts a second perimeter extrusion that is different from the perimeter extrusion.  
     
     
         40 . A panel assembly manufactured by the method of  claim 35 .  
     
     
         41 . A method for manufacturing a panel assembly, comprising the steps of: 
 engaging at least one shaping member with at least one panel, at least one perimeter extrusion engaging at least one peripheral edge of the at least one panel;    folding the at least one panel about the at least one shaping member to form at least one fold having at least substantially the same shape as at least a portion of the at least one shaping member; and    engaging at least one stiffening member with the at least one shaping member and the at least one perimeter extrusion to hold the at least one shaping member in position against the interior surface.    
     
     
         42 . The method of  claim 41 , further comprising after the folding step: 
 placing at least one stiffening member adjacent to the panel surface and rotating the at least one stiffening member into contact with the at least one shaping member and the at least one perimeter framing member.    
     
     
         43 . The method of  claim 41 , further comprising before the engaging step: 
 engaging the at least one perimeter extrusion with the at least one peripheral edge of the panel.    
     
     
         44 . The method of  claim 41 , wherein the at least one stiffening member has at least one second end in addition to the at least one end and the at least one second end contacts a second of the at least one perimeter extrusion.  
     
     
         45 . A panel assembly manufactured by the method of  claim 41 .  
     
     
         46 . A method for manufacturing a panel assembly, comprising: 
 contacting a shaping member with a surface of a panel; and    folding the panel around at least a portion of the shaping member and engaging the panel with a form having at least substantially the same shape as the shaping member to form a fold having at least substantially the same shape as the shaping member.    
     
     
         47 . The method of  claim 46 , wherein in the engaging step a first surface of the panel contacts the form and an opposing second surface of the panel contacts the shaping member.  
     
     
         48 . A panel system for engagement with a structural member, comprising: 
 at least one panel having a bend;    means for shaping said panel; said means contacting the interior of said bend and extending substantially along the length of said bend; and    stiffening means for holding the shaping means in position against the interior of said bend.    
     
     
         49 . A panel system for engagement with a structural member, comprising: 
 at least one panel having a core and a radiused fold; said panel also having a portion wherein the core of the panel is exposed; and    a radiused shaping member contacting the interior surface of the fold at the exposed portion and extending at least a substantial length of the fold.