Angle joint for sandwich panels and method of fabricating same

Abstract

An angle joint between two sandwich panels, wherein the sandwich panels each have a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an angle edge including an edge portion of the panel core and an edge portion of the first outer layer. The joint has an interface between the panel cores and the interface has an entranceway at an inner corner comprised of the edge portions of the first outer layers. A cavity in the panel cores is defined by a portion of the second outer layers and a portion of each panel core. The cavity spans across a second entranceway to the interface between panel cores. Bonding material applied in the cavity and at the inner corner connects the sandwich panels together in a manner that maintains an area of dead air space at the interface to inhibit or to reduce thermal transmissions across the joint.

1 . An angle joint between a first sandwich panel and a second sandwich panel, the angle joint comprising:
 a first sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an angle edge comprised of an edge portion of the panel core and an edge portion of the first outer layer;   a second sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an angle edge comprised of an edge portion of the panel core and an edge portion of the first outer layer, wherein the angle edges of the sandwich panels are in contact with one another at an interface between the panel cores, an entranceway to the interface between the panel cores at an inner corner comprised of the edge portions of the first outer layers;   a cavity in the panel cores, the cavity defined by a portion of the second outer layers and a portion of each panel core, the cavity spanning across a second entranceway to the interface between panel cores; and   bonding material in the cavity and at the inner corner to connect the first sandwich panel to the second sandwich panel.   
   
   
       2 . The joint of  claim 1 , further comprising a pathway through at least one of the second outer layers to the cavity and through which the bonding material is injectable. 
   
   
       3 . The joint of  claim 2 , wherein the pathway is a gap between an edge of the second outer layer of the first sandwich panel and an edge of the second outer layer of the second sandwich panel. 
   
   
       4 . The joint of  claim 3 , further comprising an outer corner comprised of bonding material between the edges of the second outer layers. 
   
   
       5 . The joint of  claim 2 , wherein the pathway is a hole formed in the second outer layer of at least one of the sandwich panels. 
   
   
       6 . The joint of  claim 5 , wherein the angle edge of each sandwich panel further comprises an edge portion of the second outer layer of the sandwich panel, and the joint further comprises an outer corner comprised of the edge portions of the second outer layer of each sandwich panel. 
   
   
       7 . The joint of  claim 1 , wherein the cavity extends along a length of the second outer layer of each sandwich panel, wherein the length of the cavity along the second outer layer is at least seven times greater than a thickness of the second outer layer. 
   
   
       8 . The joint of  claim 7 , wherein the cavity extends perpendicularly from the second outer layer of each sandwich panel along a length of the panel core, wherein the length of the cavity extending perpendicularly into the panel core is at least seven times greater than the thickness of the second outer layer. 
   
   
       9 . The joint of  claim 1 , wherein the bonding material in the cavity and at the inner corner seals entranceway to the interface between the panel cores, and the interface is dead air space. 
   
   
       10 . The joint of  claim 9 , wherein the interface between the sandwich panel cores inhibits thermal transmissions across the joint from the first outer layer to the second outer layer. 
   
   
       11 . The joint of  claim 1 , wherein the bonding material at the inner corner has a radius. 
   
   
       12 . The joint of  claim 1 , wherein the panel cores are comprised of insulating materials and the first and second outer layers are comprised of composite materials. 
   
   
       13 . A method of joining two sandwich panels in a non-linear orientation, the sandwich panels having a core, an outer layer covering at least one surface of the core, an angle edge and a cavity, the method comprising:
 placing the panels edge to edge to form an interface in an area between the panel cores and a combined cavity; and   applying bonding material in the cavity to hold the panels together and to block thermal transmissions across the joint.   
   
   
       14 . The method of  claim 13 , wherein the applying step further comprises injecting bonding material into the cavity through a gap in the edges of the outer layers of the sandwich panels. 
   
   
       15 . The method of  claim 13 , wherein the applying step further comprises injecting bonding material into the cavity through at least one hole in at least one of the outer layers. 
   
   
       16 . The method of  claim 13 , wherein the sandwich panels have a second outer layer covering at least one surface of the core, and wherein the placing step further comprises placing the second outer layers edge to edge to form an inner corner of the joint. 
   
   
       17 . The method of  claim 16 , further comprising applying bonding material at the inner corner of the joint. 
   
   
       18 . A method of joining two sandwich panels with an angle joint, wherein each sandwich panel has a first outer layer and a second outer layer spaced from the first outer layer by a panel core, the method comprising:
 removing an edge portion of each panel to form an angle edge, the angle edge comprising a portion of the panel core and an edge of the first outer layer;   placing the angle edges in contact with one another, such that there is an interface between the panel cores and the edges of the first outer layers are in contact with one another to form an inner corner and an entranceway to the interface;   forming a cavity by removing a portion of the panel core, the cavity defined by a portion of the second outer layer of each sandwich panel and a portion of the core;   filling the cavity with a bonding material that spans across a second entranceway to the interface; and   applying bonding material that spans across the entranceway at the inner corner.   
   
   
       19 . The method of  claim 18 , wherein the step of forming the cavity comprises removing a portion of the core near the second outer layer of each sandwich panel and a portion of the panel core extending perpendicularly from the second outer layer of each sandwich panel. 
   
   
       20 . The method of  claim 18 , wherein step of forming a cavity comprises removing a portion of the panel core near the second outer layer of each sandwich panel that has a length that is at least seven times a thickness of the second outer layer. 
   
   
       21 . The method of  claim 20 , wherein step of forming a cavity comprises removing a portion of the panel core extending perpendicularly from the second outer layer of each sandwich panel that has a length that is at least seven times the thickness of the second outer layer. 
   
   
       22 . The method of  claim 18 , further comprising the step of forming a pathway to the cavity by removing a portion of the second outer layer of at least one of the sandwich panels. 
   
   
       23 . The method of  claim 22 , comprising removing a portion from the second outer layer of at least one of the sandwich panels to form a hole. 
   
   
       24 . The method of  claim 22 , wherein the step of forming a pathway comprises removing a strip of the second outer layer from each of the sandwich panels to form an edge of the second outer layer of each sandwich panel, wherein the edges of the second layers are spaced from one another to form a gap. 
   
   
       25 . The method of  claim 22 , further comprising spreading bonding material between the edges of the second outer layers to form an outer corner. 
   
   
       26 . The method of  claim 18 , further comprising installing the sandwich panels are as part of a monolithic building. 
   
   
       27 . A sandwich panel comprised of:
 a first outer layer and a second outer layer, the outer layers separated from one another by an insulative core;   an angle edge comprised of a portion of the insulative core and a portion of the first outer layer;   a cavity in the insulative core, the cavity defined by a portion of the second outer layer and a portion of the core; and   a pathway through the second outer layer to the cavity through which a bonding material may be injected to form an angle joint between the sandwich panel and an adjacent construction element, wherein the insulative core inhibits thermal transfer across the joint from the first outer layer to the second outer layer.   
   
   
       28 . A method of forming a sandwich panel comprising:
 mounting a first outer layer to a core;   mounting a second outer layer to the core;   forming an angle edge of the sandwich panel, the angle edge comprising a portion of the first outer layer and a portion of the core;   forming a cavity between a portion of the second outer layer and a portion of the core; and   providing access to the cavity through the second outer layer with a pathway through which bonding material is injectable to form a joint between the angle edge of the sandwich panel and a construction element in a manner that inhibits thermal transmissions across the joint.