Method of manufacturing a composite panel

Abstract

Embodiments of the disclosure pertain to a method of manufacturing a composite panel that includes the steps of providing a layer of porous material, and dispersing a particulate material further comprising a binder composition mixed therein onto the layer of porous material. The method includes using a vacuum to at least substantially retain the particulate material on the layer of porous material, and conveying the retained particulate material toward an application mechanism. The method also includes using the application mechanism to associate a polymeric substrate with the particulate material, and applying a backing layer onto the polymeric substrate and the particulate material. The method further includes containing the retained particulate material, the polymeric substrate, and the backing layer together for a period of time to cure the polymeric substrate, the particulate material, and the backing layer together; and completing the composite panel by removing the layer of porous material therefrom, and cleaning off residual therefrom.

What is claimed is: 
     
         1 . A method of manufacturing a composite panel, the method comprising:
 providing a layer of porous material;   dispersing a particulate material further comprising a binder composition mixed therein onto the layer of porous material;   using a vacuum to at least substantially retain the particulate material on the layer of porous material;   conveying the retained particulate material toward an application mechanism;   using the application mechanism to associate a polymeric substrate with the particulate material;   applying a backing layer onto the polymeric substrate and the particulate material;   containing the particulate material, the polymeric substrate, and the backing layer together for a period of time to cure the polymeric substrate, the particulate material, and the backing layer together; and   completing the composite panel by cleaning off any residual therefrom.   
     
     
         2 . The method of  claim 1 , the method comprising affixing a plurality of finish elements to the completed composite panel. 
     
     
         3 . The method of  claim 2 , wherein the finish elements comprise stone, and at least two stone finish elements are of different size and dimension to each other, and the method further comprises affixing the plurality of finish elements to the completed composite panel in an uneven manner. 
     
     
         4 . The method of  claim 3 , wherein polymeric substrate has a thermal insulating characteristic defining an air and moisture infiltration barrier within said composite panel. 
     
     
         5 . The method of  claim 1 , the method further comprising: repeating the steps to complete a plurality of composite panels, and fastening the plurality of composite panels to a structure. 
     
     
         6 . The method of  claim 5 , after fastening the plurality of composite panels to the structure, then affixing a plurality of finish elements to the completed composite panel. 
     
     
         7 . The method of  claim 1 , the method further comprising using an alignment jig. 
     
     
         8 . A method of manufacturing a composite panel, the method comprising:
 providing a layer of porous material;   dispersing from a feeder a particulate material onto the layer of porous material;   using a vacuum to at least substantially retain the particulate material on the layer of porous material;   conveying the particulate material toward an application mechanism;   operating the application mechanism to cause a polymeric substrate to be proximately associated with the particulate material;   applying a backing layer onto the associated polymeric substrate and particulate material;   containing the particulate material, the polymeric substrate, and the backing layer together for a predetermined period of time to cure the polymeric substrate, the particulate material, and the backing layer together; and   completing the composite panel by removing the layer of porous material therefrom.   
     
     
         9 . The method of  claim 8 , the method comprising affixing a plurality of finish elements to the completed composite panel. 
     
     
         10 . The method of  claim 9 , wherein the finish elements comprise stone, and the method further comprises affixing the plurality of finish elements to the completed composite panel in an uneven manner. 
     
     
         11 . The method of  claim 11 , wherein polymeric substrate has a thermal insulating characteristic defining an air and moisture infiltration barrier within said composite panel. 
     
     
         12 . The method of  claim 10 , the method further comprising:
 repeating the steps to complete a plurality of composite panels;   fastening the plurality of composite panels to a structure; and   after fastening the plurality of composite panels to the structure, then affixing a plurality of finish elements to the completed composite panel.   
     
     
         13 . The method of  claim 12 , the method further comprising using an alignment jig. 
     
     
         14 . A method of manufacturing a composite panel, the method comprising:
 providing a layer of porous material;   dispersing from a feeder a particulate material onto the layer of porous material;   positioning an alignment jig within the particulate material;   using a vacuum to at least substantially retain the particulate material on the layer of porous material;   conveying the particulate material toward an application mechanism;   operating the application mechanism to associate a polymeric substrate with the particulate material;   applying a backing layer onto the associated polymeric substrate and particulate material;   containing the associated particulate material and polymeric substrate, and the backing layer together for a predetermined period of time to cure the polymeric substrate, the particulate material, the alignment jig, and the backing layer together; and   completing the composite panel by cleaning any residual therefrom.   
     
     
         15 . The method of  claim 14 , the method comprising affixing a plurality of finish elements to the completed composite panel. 
     
     
         16 . The method of  claim 15 , wherein the finish elements comprise stone, and the method further comprises affixing the plurality of finish elements to the completed composite panel in an uneven manner. 
     
     
         17 . The method of  claim 16 , wherein the polymeric substrate has a thermal insulating characteristic defining an air and moisture infiltration barrier within said composite panel. 
     
     
         18 . The method of  claim 14 , the method further comprising:
 repeating the steps to complete a plurality of composite panels;   fastening the plurality of composite panels to a structure; and   after fastening one or more of the plurality completed of composite panels to the structure, then affixing a plurality of finish elements to the respective one or more completed composite panel.