Architectural composite panels and composite systems

Abstract

Composite panels and cladding systems for use in architectural projects are disclosed. The composite panels include a base layer having a plurality of perforations or apertures formed therein and a mesh layer, wherein woven strands of the mesh layer are visible, engage and/or extend through the perforated base layer. The mesh layer is preferably a woven metallic mesh or fabric. The cladding systems of the present invention include a plurality of composite panels configured to cover a large surface area, such as a wall, railing or ceiling.

1 . A composite building panel comprising:
 a mesh layer having first and second surfaces and comprising a plurality of woven strands, each of the first and second surfaces including a pattern of outwardly extending projections; and   a base layer aligned with and overlying the mesh layer, the base layer including a plurality of apertures formed therein arranged in substantially the same pattern as the outwardly extending projections on the first surface of the mesh layer such that at least a portion of the projections on the first surface of the mesh layer are visible through the apertures.   
   
   
       2 . The composite panel of  claim 1 , wherein the mesh layer comprises a plurality of interwoven wire strands, wherein the wire strands are constructed of a metal material selected from steel, aluminum and aluminum alloys, copper and copper alloys, nickel and nickel alloys, silver, titanium or any suitable wire material and combinations thereof. 
   
   
       3 . The composite panel of  claim 1 , wherein the mesh layer is constructed of a material selected from wood, plastic, glass, fiberglass, polycarbonates, acrylics and combinations thereof. 
   
   
       4 . The composite panel of  claim 1 , wherein the base layer is constructed of a metal material selected from steel, aluminum and aluminum alloys, copper and copper alloys, nickel and nickel alloys, silver, titanium or any suitable wire material and combinations thereof. 
   
   
       5 . The composite panel of  claim 1 , wherein the base layer is constructed of a material selected from wood, plastic, glass, fiberglass, polycarbonates, acrylics and combinations thereof. 
   
   
       6 . The composite panel of  claim 1 , wherein the base layer has a first and a second surface and wherein at least one of the first and second surfaces is etched, stamped, embossed, anodized, painted, coated or a combination thereof. 
   
   
       7 . The composite panel of  claim 1 , wherein the mesh layer and the base layer are secured together by at least one of adhesives, welds and fasteners. 
   
   
       8 . The composite panel of  claim 1 , wherein each of the base layer and the mesh layer has a side edge, and wherein the side edge of the base layer is in pivotal engagement with the side edge of the mesh layer. 
   
   
       9 . The composite panel of  claim 1 , wherein each of the base layer and the mesh layer are provided with a radius of curvature to provide the composite panel with an arcuate surface. 
   
   
       10 . A composite panel comprising:
 a mesh layer comprising a plurality of interwoven wire strands, each of the interwoven wire strands having a length provided with a plurality of crimps; and   a substantially planar member positioned close adjacent to the mesh layer and secured thereto, wherein the planar member includes apertures formed therein configured such that a least a portion the crimped wire strands are visible through the apertures in the planar member.   
   
   
       11 . The composite panel of  claim 10 , wherein the mesh layer is preferably a metallic mesh material. 
   
   
       12 . The composite panel of  claim 10 , wherein the planar member is a metallic sheet. 
   
   
       13 . The composite panel of  claim 10 , wherein the planar member comprises first and second surfaces and wherein the planar member is at least one of embossed, etched and stamped to provide decorative indicia on at least one of its first and second surfaces. 
   
   
       14 . The composite panel of  claim 10 , wherein the mesh layer and the planar member are contiguously secured together by at least one of welds, fasteners and adhesives. 
   
   
       15 . An architectural surface system comprising:
 a plurality of composite panels joined contiguously together at the respective edges thereof, wherein each of the composite panels comprises a metallic mesh layer provided with a pattern of crimps and a base layer having a plurality of apertures formed therein, wherein the mesh layer is secured adjacent to the base layer such that at least a portion of the crimps within the mesh layer are visible through the apertures in the base layer.   
   
   
       16 . The architectural surface system of  claim 15 , wherein at least a portion of the crimps extend at least partially through the apertures in the base layer. 
   
   
       17 . The architectural surface system of  claim 15 , wherein at least a portion of the composite panels comprise a first metallic mesh layer and wherein at least a portion of the composite panels comprise a second metallic mesh layer. 
   
   
       18 . The architectural surface system of  claim 15 , wherein at least a portion of the composite panels comprise a first base layer and wherein at least a portion of the composite panels comprise a second base layer.