# US 10,479,016 B2 · Polycarbonate panel having shallow bends

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- Number: US 10,479,016 B2
- Document ID: US10479016B2
- Status: Granted
- Kind: B2
- Application number: 15/006,831
- Filed: 2016-01-26
- Published: 2016-07-28
- Granted: 2019-11-19
- Earliest claimed: 2015-01-26
- Applicants: Stephen J. Motosko; Catherine Motosko; Stephen Motosko, III
- Inventors: Stephen J. Motosko; Catherine Motosko; Stephen Motosko, III
- Web page: https://patentgrep.com/patent/US10479016B2

## CPC

- B29C 51/082: {by shaping between complementary mould parts}
- B29C 51/16: Lining or labelling
- B29C 51/264: {Auxiliary operations prior to the thermoforming operation, e.g. cutting (B29C51/42, B29C51/46 take precedence)}
- B29C 51/421: {of preforms, specially adapted for thermoforming (preheating sheets in general B29B13/023; B29C51/427 takes precedence)}
- B29C 51/46: Measuring, controlling or regulating
- B29C 53/24: of plates or sheets
- E04C 2/20: of plastics
- E04C 2/322: {with parallel corrugations}
- E04C 2/328: {slightly bowed or folded panels not otherwise provided for}
- E04C 2/50: {Self-supporting slabs specially adapted for making floors ceilings, or roofs, e.g. able to be loaded (E04C2/52, E04C2/54 take precedence; structures of slab-shaped elements E04B1/02; floor structures E04B5/00; roofs consisting of self-supporting slabs E04B7/20; ceilings E04B9/00; roof coverings E04D; floor coverings E04F15/00)}
- E06B 9/02: Shutters, movable grilles, or other safety closing devices, e.g. against burglary (louvre windows or grilles E06B7/08; lamellar blinds E06B9/26)
- B29C 51/445: {from a support after moulding, e.g. by cutting}
- B29K 2023/06: {PE, i.e. polyethylene}
- B29K 2069/00: Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material
- B29L 2009/00: Layered products
- B29L 2016/00: Articles with corrugations or pleats (B29L2023/18, {B29L2024/003} take precedence)
- E04H 9/14: against other dangerous influences, e.g. tornadoes, floods
- E06B 2009/005: {Storm panels; hurricane shutters}
- Y02A 50/00: in human health protection, e.g. against extreme weather
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- E06B: FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES (shades or blinds for greenhouses A01G9/22; curtains A47H; lids for car boots or bonnets B62D25/10; skylights E04B7/18; sunshades, awnings E04F10/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- E04H: BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL (foundations E02D)
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE

## Abstract

A panel having a base portion having at least one sidewall extending therefrom, the sidewall extending away from the base portion at a first predetermined angle, the first predetermined angle formed by a die having a second predetermined angle, the second predetermined angle being 1 to 12 degrees smaller as compared to the first predetermined angle so as to overbend the panel during the forming process, the panel relaxing to the first predetermined angle after the panel as entirely cooled after the forming process.

## Claims

### Claim 1

A method for forming multiple bends into a panel comprising the steps of:
providing first and second opposing and elongated dies, the first die having in cross section a projecting profile and the second die a recessed profile extending between a pair of outer edge portions for receiving the projecting profile;
heating a surface of at least one of the first and second dies to a temperature up to 110° F.;
providing the panel of a polycarbonate material at an ambient temperature and advancing the panel to a first location between the first and second elongated dies so that a surface of the panel is placed into proximity with the heated surface, resulting in a temperature increase of the panel while retaining its structural rigidity;
displacing the projecting profile into the recessed profile to compress a portion of the panel sandwiched between the dies and to initially deform the panel;
pinching the sandwiched portion of the panel at first and second interior locations between the dies;
forming the panel by stretching and further bending the panel in the die at the pinch locations to define a thinned portion of the panel and in order to alter a molecular structure of the panel between the pinch locations resulting in strengthening of the panel;
separating the dies and subsequently advancing the panel to at least a second location and repeating of the steps of displacing, pinching and forming the panel in order to reform the panel to exhibit multiple strengthened bends.

### Claim 2 (depends on 1)

The method of claim 1 further comprising the step of the panel being over bent by 1 to 12 degrees during forming.

### Claim 3 (depends on 1)

The method of claim 1, further comprising the step of providing at least the projecting profile with a rounded bottom portion.

### Claim 4 (depends on 3)

The method of claim 3, further comprising the step of configuring both the projecting and recessed profiles with opposing arcuate profiles.

### Claim 5 (depends on 3)

The method of claim 3, further comprising the step of positioning the pinch points on opposite sides of the rounded bottom of the projecting profile.

### Claim 6 (depends on 1)

The method of claim 1, further comprising the step of providing a polycarbonate roll of material and sectioning the roll material into individual panels.

### Claim 7 (depends on 1)

The method of claim 1, further comprising the step of pre-applying a protective polyethylene layer to the panel prior to forming between the dies.