Multi-layer panel and method of manufacturing such a panel

• US 8,034,263 B2
• Filed: 12/19/2008
• Issued: 10/11/2011
• Est. Priority Date: 07/14/2008
• Status: Expired due to Fees

• Current Assignee: Musion IP Ltd. (Musion DAS Hologram Limited)
• Original Assignee: Musion IP Ltd. (Musion DAS Hologram Limited)
• Inventors: Maass, Uwe
• Primary Examiner(s): Vargot; Mathieu D.
• Application Number:
  US12/340,157
• Publication Number:
  US 20100007959A1
• Time in Patent Office: 1,026 Days
• Field of Search: 264/1.1, 264/1.7, 264/1.9, 264/255, 264/313, 264/314, 264/308, 264/315, 425/808
• US Class Current: 264/1.9
• CPC Class Codes: B29D 11/00596 Mirrors
• CPC Class Codes: H04N 7/15 Conference systems

Abstract

A method of manufacturing a multi-layer panel having a curved reflective and/or transmitting facing layer that includes the steps of increasing and/or decreasing pressure on a side of a thin membrane to form a pressure differential across the thin membrane that causes the thin membrane to deform to a required shape; applying a first layer of material to an outer surface of the thin membrane while the thin membrane is maintained in the required shape by the increase and/or decrease in pressure, and allowing the first layer of material to cure for a pre-determined time.

Claims

1. A method of manufacturing a multi-layer panel having a curved reflective and/or transmitting facing layer, the method comprising the steps of:

clamping a thin membrane between an inner circular frame and outer circular frame the inner circular frame and the outer circular frame forming a frame;

placing the frame and the thin membrane on top of a pressure chamber;

temporarily sealing the frame and the thin membrane to the pressure chamber so that an airtight seal is formed between the frame and the pressure chamber;

blowing air into the pressure chamber and, under pressure or pressure differential, blowing the thin membrane up to form a required shape;

applying a first layer of material to an outer surface of the thin membrane while the thin membrane is maintained in the required shape;

allowing the first layer of material to cure for a first predetermined time;

applying a second layer of material to the first layer of material while the thin membrane is maintained in the required shape; and

allowing the second layer of material to cure for a second predetermined time, the second layer of material reinforcing the first layer of material.

2. The method of claim 1, wherein the thin membrane comprises a thin plastic film or a thin foil and the frame and thin membrane are temporarily sealed to the pressure box or chamber using release clamps.

3. The method of claim 1, further comprising the step of attaching an o-ring to either the thin membrane or the frame.

4. The method of claim 1, wherein when the pressure chamber is pressurised the thin membrane forms a concave shape and when the pressure chamber is depressurised the thin membrane forms a convex shape.

5. The method of claim 1, wherein the required shape of the thin membrane is a parabolic shape.

6. The method of claim 1, further comprising the step of abrading the outer surface of the thin membrane while still under a pressure differential to provide a mechanical key to the outer surface of the thin membrane.

7. The method of claim 1, wherein the first layer of material comprises a plastic material that is cured by the application of a catalyst or low heat.

8. The method of claim 1, wherein the first layer of material comprises any one of the group of materials comprising polyesters, epoxies, silicones, and polyurethanes.

9. The method of claim 1, wherein the first layer of material is a slow curing material.

10. The method of claim 1, wherein the first layer of material comprises filler to increase the viscosity of the first layer material.

11. The method of claim 10, wherein the filler is aluminium.

12. The method of claim 1, wherein the first layer of material comprises a black dye added to the first layer of material to enhance the reflectivity of the first layer of material.

13. The method of claim 1, wherein the second layer of material comprises a fibre glass mat impregnated with a polyester resin, the polyester resin cured by mixing the polyester resin with a suitable catalyst.

14. The method of claim 1, wherein the first predetermined time and the second predetermined time ranges from a few minutes up to 24 hours.