WO2014153660A1 - Decorative panel and method of producing the same - Google Patents

Decorative panel and method of producing the same Download PDF

Info

Publication number
WO2014153660A1
WO2014153660A1 PCT/CA2014/050310 CA2014050310W WO2014153660A1 WO 2014153660 A1 WO2014153660 A1 WO 2014153660A1 CA 2014050310 W CA2014050310 W CA 2014050310W WO 2014153660 A1 WO2014153660 A1 WO 2014153660A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam board
decorative panel
front surface
adhesive
back surface
Prior art date
Application number
PCT/CA2014/050310
Other languages
French (fr)
Inventor
Al Cormier
Original Assignee
Ferri, Domenico
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ferri, Domenico filed Critical Ferri, Domenico
Publication of WO2014153660A1 publication Critical patent/WO2014153660A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
    • E04F13/165—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips with an outer layer imitating natural stone, brick work, tiled surface or the like

Definitions

  • the present invention generally relates to decorative panel. More particularly, it relates to a decorative panel addressing structural or decorative needs in the construction industry. The invention also relates to a method of producing such panels. BACKGROUND OF THE INVENTION
  • An object of the present invention is to propose a panel and method that satisfies at least one of the above-mentioned needs.
  • a decorative panel comprising:
  • a method of producing a decorative panel comprising the steps of:
  • a condensed foam board having a front surface and a back surface
  • Figure 1 is a front view of two decorative panels in accordance with sample embodiments of the present invention.
  • Figure 2 is a side view of one of the two panels shown in Figure 1 , including a resilient element on the back surface.
  • Figure 3 is a side view of the other panel shown in Figure 1 . PREFERRED EMBODIMENTS OF THE PRESENT INVENTION
  • An object of the present invention is to decorative panels as illustrated in Figures 1
  • the decorative panel includes a condensed foam board 10 having a front surface 12 and a back surface 14.
  • An adhesive element 16 is applied to the back surface 14.
  • the front surface 12 of the foam board 10 is subjected to heat stamping or pressure embossing.
  • a colorant is injected or applied to the foam board.
  • a decorative element is laminated or applied to the foam board.
  • a protective clear coat can be applied to the front surface.
  • the adhesive element is a removable adhesive or a permanent adhesive.
  • the adhesive can preferably perform like gel tack.
  • a removable protective liner can be applied over the adhesive element.
  • a resilient element (such as a spongy element or a component behaving in a similar manner) is positioned between the foam board 12 and the adhesive element 16.
  • the resilient element would allow the decorative panel to be installed on uneven surfaces more easily in certain scenarios.
  • a number of slits can be formed in the back surface of the foam board to give the board flexibility to adapt to different installation surfaces.
  • a method of producing a decorative panel comprising the steps of: a) providing a condensed foam board having a front surface and a back surface;
  • the method can further comprise the step of injecting or applying a colorant to the foam board. In some embodiments, the method can further comprise the step of laminating or applying a decorative element to the foam board.
  • the method can further comprise the step of, after step c), applying a protective clear coat to the front surface.
  • the method can further comprise a step of applying a removable protective liner over the adhesive element.
  • the present invention generally relates to a lighter application of a special effects brick design, which can be removable without damaging the wall surface.
  • the condensed foam board can range in thickness from one quarter inch to several inches thick.
  • the foam board will be heat stamped or pressure embossed with specific dies to create special effects with brick or faux-fini patterns.
  • the foam board can be injected or dyed with certain colors or laminated with materials to create special effects when heat stamped or pressure embossed. After heat stamping or pressure embossing, one can apply texture or rock powder or colorants which will be sprayed directly on the product to also create different textures and effects.
  • One can also apply a protective clear coat to the finished product to promote durability, protect against discoloration and to allow for interior and exterior use.
  • This product can have a removable or permanent adhesive applied directly to its rear surface, and a protective liner which will protect this adhesive, and be removable when product is ready to be applied by clients.
  • the product is much lighter than the brick or plaster products similar to it on the market. These products (plaster) have to be poured into moulds which makes it very time consuming and expensive for manufacturing.
  • the product in accordance with the present invention can be made from foam board sheets which will be on a conveyer belt, which will be heat stamped or pressure embossed by a machine at a very fast rate, which makes this product retail at a more competitive and reduced cost.
  • the foam board is made from expanded polystyrene (EPS).
  • EPS expanded polystyrene
  • Fire proof EPS panels do not typically pass national fire safety codes.
  • Fire proof paint does not pass national fire safety codes on normal EPS panels.
  • a combination of these two products make the EPS panels pass certain national fire safety codes.
  • the thermostatically heat regulated dyes will range in temperature between 40 degrees Fahrenheit & 750 degrees Fahrenheit.
  • Pressure of the press can also be regulated to create the effects in the process of being created.
  • the panels can be provided as 1 'x2' panels with interlocking elements, tabs or mechanisms on edges thereof. These interlocking elements can extend for example 3" from an edge of the panel.
  • the dye cut forming the panel can be arranged such that the interlocking element can be snapped out or left in for different scenarios (for example, when a panel falls onto an edge of a wall and the interlocking element is not required.)

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)

Abstract

The decorative panel includes a condensed foam board having a front surface and a back surface. An adhesive element is applied to the back surface. The front surface of the foam board is subjected to heat stamping or pressure embossing. The panel can be thus manufactured at a more competitive and reduced cost. It also allows the product to be more client-friendly as it can be easily cut and placed by the client versus other products on the market which require more work to cut and place and, in most cases, requires the client to hire a professional to assist in its application on building surfaces.

Description

DECORATIVE PANEL AND METHOD OF PRODUCING THE SAME
FIELD OF THE INVENTION The present invention generally relates to decorative panel. More particularly, it relates to a decorative panel addressing structural or decorative needs in the construction industry. The invention also relates to a method of producing such panels. BACKGROUND OF THE INVENTION
Variously decorated panels are used as structural or decorative elements in the construction field. Certain panels with embossed or textured surfaces, such as brick or various plaster panels, can be extremely heavy and difficult to install for an ordinary consumer.
Consequently, there is a need for a panel and method for producing the same that avoids this prior art problem.
SUMMARY OF THE INVENTION
An object of the present invention is to propose a panel and method that satisfies at least one of the above-mentioned needs.
According to the present invention, that object is accomplished with a decorative panel comprising:
-a condensed foam board having a front surface and a back surface;
-an adhesive element applied to the back surface, wherein the front surface of the foam board is subjected to a treatment selected from the group comprising heat stamping and pressure embossing.
According to the present invention, there is also provided a method of producing a decorative panel comprising the steps of:
a) providing a condensed foam board having a front surface and a back surface;
b) subjecting the front surface of the foam board to a treatment selected from the group comprising heat stamping and pressure embossing; and
c) applying an adhesive element to the back surface.
A non-restrictive description of a preferred embodiment of the invention will now be given with reference to the appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a front view of two decorative panels in accordance with sample embodiments of the present invention. Figure 2 is a side view of one of the two panels shown in Figure 1 , including a resilient element on the back surface.
Figure 3 is a side view of the other panel shown in Figure 1 . PREFERRED EMBODIMENTS OF THE PRESENT INVENTION
An object of the present invention is to decorative panels as illustrated in Figures 1 The decorative panel includes a condensed foam board 10 having a front surface 12 and a back surface 14. An adhesive element 16 is applied to the back surface 14. The front surface 12 of the foam board 10 is subjected to heat stamping or pressure embossing.
In some embodiments, a colorant is injected or applied to the foam board.
In some embodiments, a decorative element is laminated or applied to the foam board.
In some embodiments, a protective clear coat can be applied to the front surface.
In some embodiments, the adhesive element is a removable adhesive or a permanent adhesive. The adhesive can preferably perform like gel tack.
In some embodiments, a removable protective liner can be applied over the adhesive element.
In some embodiments, as better shown in Figure 2, a resilient element (such as a spongy element or a component behaving in a similar manner) is positioned between the foam board 12 and the adhesive element 16. The resilient element would allow the decorative panel to be installed on uneven surfaces more easily in certain scenarios. In some embodiments, a number of slits can be formed in the back surface of the foam board to give the board flexibility to adapt to different installation surfaces.
According to the present invention, there is also provided a method of producing a decorative panel comprising the steps of: a) providing a condensed foam board having a front surface and a back surface;
b) subjecting the front surface of the foam board to a treatment selected from the group comprising heat stamping and pressure embossing; and
c) applying an adhesive element to the back surface.
In some embodiments, the method can further comprise the step of injecting or applying a colorant to the foam board. In some embodiments, the method can further comprise the step of laminating or applying a decorative element to the foam board.
In some embodiments, the method can further comprise the step of, after step c), applying a protective clear coat to the front surface.
In some embodiments, the method can further comprise a step of applying a removable protective liner over the adhesive element.
In some embodiments, the method can further comprise inserting a resilient element between the foam board and the adhesive element.
The present invention generally relates to a lighter application of a special effects brick design, which can be removable without damaging the wall surface. The condensed foam board can range in thickness from one quarter inch to several inches thick. The foam board will be heat stamped or pressure embossed with specific dies to create special effects with brick or faux-fini patterns. The foam board can be injected or dyed with certain colors or laminated with materials to create special effects when heat stamped or pressure embossed. After heat stamping or pressure embossing, one can apply texture or rock powder or colorants which will be sprayed directly on the product to also create different textures and effects. One can also apply a protective clear coat to the finished product to promote durability, protect against discoloration and to allow for interior and exterior use. This product can have a removable or permanent adhesive applied directly to its rear surface, and a protective liner which will protect this adhesive, and be removable when product is ready to be applied by clients. The product is much lighter than the brick or plaster products similar to it on the market. These products (plaster) have to be poured into moulds which makes it very time consuming and expensive for manufacturing. The product in accordance with the present invention can be made from foam board sheets which will be on a conveyer belt, which will be heat stamped or pressure embossed by a machine at a very fast rate, which makes this product retail at a more competitive and reduced cost. It also allows the product to be more client-friendly as it can be more easily cut and placed by the client as opposed to other products on the market which require more work to cut and place and, in most cases, requires the client to hire a professional to assist in its application on building surfaces. In other embodiments for exterior uses of the panel, additional fixing elements such as support straps or the like can be provided to affix the panel to a structure.
Preferably, the foam board is made from expanded polystyrene (EPS). Fire proof EPS panels do not typically pass national fire safety codes. Fire proof paint does not pass national fire safety codes on normal EPS panels. A combination of these two products make the EPS panels pass certain national fire safety codes.
Preferably, the thermostatically heat regulated dyes will range in temperature between 40 degrees Fahrenheit & 750 degrees Fahrenheit. Depending on the type of logo, pattern or design pressed into the (EPS) Foam board. Pressure of the press can also be regulated to create the effects in the process of being created. In certain embodiments, the panels can be provided as 1 'x2' panels with interlocking elements, tabs or mechanisms on edges thereof. These interlocking elements can extend for example 3" from an edge of the panel. In certain panels, the dye cut forming the panel can be arranged such that the interlocking element can be snapped out or left in for different scenarios (for example, when a panel falls onto an edge of a wall and the interlocking element is not required.)
The techniques described above could also be used to produce a heat-pressed decorative work of art.
Although preferred embodiments of the present invention have been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to these precise embodiments and that various changes and modifications can be effected therein without departing from the scope of the present invention.

Claims

1 . A decorative panel comprising:
-a condensed foam board having a front surface and a back surface;
-an adhesive element applied to the back surface,
wherein the front surface of the foam board is subjected to a treatment selected from the group comprising heat stamping and pressure embossing.
2. The decorative panel according to claim 1 , wherein a colorant is injected or applied to the foam board.
3. The decorative panel according to claim 1 or 2, wherein a decorative element is laminated or applied to the foam board.
4. The decorative panel according to any one of claims 1 to 3, further comprising a protective clear coat applied to the front surface.
5. The decorative panel according to any one of claims 1 to 4, wherein the adhesive element is selected from the group comprising removable adhesive and permanent adhesive.
6. The decorative panel according to claim 5, further comprising a removable protective liner applied over the adhesive element.
7. The decorative panel according to any one of claims 1 to 6, further comprising a resilient element positioned between the foam board and the adhesive element.
8. The decorative panel according to any one of claims 1 to 7, wherein the foam board is made from expanded polystyrene.
9. The decorative panel according to any one of claims 1 to 8, wherein the front surface of the foam board is subjected to a temperature between 40°F and 750°F.
10. A method of producing a decorative panel comprising the steps of:
a) providing a condensed foam board having a front surface and a back surface;
b) subjecting the front surface of the foam board to a treatment selected from the group comprising heat stamping and pressure embossing; and
c) applying an adhesive element to the back surface.
1 1 . The method according to claim 10, further comprising the step of injecting or applying a colorant to the foam board.
12. The method according to claim 10 or 1 1 , further comprising the step of laminating or applying a decorative element to the foam board.
13. The method according to any one of claims 10 to 12, further comprising the step of, after step c), applying a protective clear coat to the front surface.
14. The method according to any one of claims 10 to 13, wherein the adhesive element is selected from the group comprising removable adhesive and permanent adhesive.
15. The method according to any one of claims 10 to 14, further comprising a step of applying a removable protective liner over the adhesive element.
16. The method according to any one of claims 10 to 15, further comprising inserting a resilient element between the foam board and the adhesive element.
17. The method according to any one of claims 10 to 16, wherein the foam board is made from expanded polystyrene.
18. The method according to any one of claims 10 to 17, wherein the front surface of the foam board is subjected to a temperature between 40°F and 750°F.
PCT/CA2014/050310 2013-03-26 2014-03-26 Decorative panel and method of producing the same WO2014153660A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361805278P 2013-03-26 2013-03-26
US61/805,278 2013-03-26

Publications (1)

Publication Number Publication Date
WO2014153660A1 true WO2014153660A1 (en) 2014-10-02

Family

ID=51622316

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA2014/050310 WO2014153660A1 (en) 2013-03-26 2014-03-26 Decorative panel and method of producing the same

Country Status (1)

Country Link
WO (1) WO2014153660A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018122683A1 (en) * 2016-12-28 2018-07-05 3M Innovative Properties Company Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3646180A (en) * 1969-10-24 1972-02-29 Selectile Co Inc Method of forming a foam cored wall panel having ceramic tile on one face
US5860259A (en) * 1995-05-15 1999-01-19 Laska; Walter A. Masonry insulated board with integral drainage
JP2000301645A (en) * 1999-04-19 2000-10-31 Sumitomo Chem Co Ltd Multilayer molded product and its manufacture
US20030082344A1 (en) * 2001-10-22 2003-05-01 Omnova Solutions Inc. Selectively controlling in-mold coating flow
US20030190454A1 (en) * 2002-04-03 2003-10-09 Omnova Solutions Inc. Mold runner for prevention of in-mold coating flow

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3646180A (en) * 1969-10-24 1972-02-29 Selectile Co Inc Method of forming a foam cored wall panel having ceramic tile on one face
US5860259A (en) * 1995-05-15 1999-01-19 Laska; Walter A. Masonry insulated board with integral drainage
JP2000301645A (en) * 1999-04-19 2000-10-31 Sumitomo Chem Co Ltd Multilayer molded product and its manufacture
US20030082344A1 (en) * 2001-10-22 2003-05-01 Omnova Solutions Inc. Selectively controlling in-mold coating flow
US20030190454A1 (en) * 2002-04-03 2003-10-09 Omnova Solutions Inc. Mold runner for prevention of in-mold coating flow

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018122683A1 (en) * 2016-12-28 2018-07-05 3M Innovative Properties Company Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate
CN110121417A (en) * 2016-12-28 2019-08-13 3M创新有限公司 For manufacturing method, the mold for molded sheet form lamilate and the sheet lamilate of sheet lamilate
US11292181B2 (en) 2016-12-28 2022-04-05 3M Innovative Properties Company Method for manufacturing sheet laminate
CN110121417B (en) * 2016-12-28 2022-05-10 3M创新有限公司 Method for manufacturing sheet-like laminated body, mold for molding sheet-like laminated body, and sheet-like laminated body

Similar Documents

Publication Publication Date Title
CN102627015B (en) The method manufacturing plate-like product and the plate-like product manufactured by the method
CN106985563B (en) The method that decoration is applied to composite wood board
CN107225902B (en) Paloc retro-style three-dimensional carved pattern color-coated metal plate
CN107530734A (en) The method on manufacturing structured surface and the product of such structuring
WO2007003804A3 (en) Method of producing floor covering strips, strips thus produced and facility and decorative sheet used to implement said method
CN203974170U (en) Decorative metal film
US8458907B1 (en) Method and apparatus for exterior surface treatment of insulated structural steel panels
WO2014153660A1 (en) Decorative panel and method of producing the same
CN102392585A (en) Production method of fire-proof and burglar-proof door
KR20030051663A (en) Method of selectively coating a wood composite, and coated wood composite
KR101950388B1 (en) Multi-layered polyurethane embossed composite material with dimensional enhancement
KR101117951B1 (en) Prefabricated panel and manufacturing method thereof
US20150044480A1 (en) Polyurethane impregnated paper laminate and method therefor
JP2018100502A (en) Decorative sheet and decorative board
CN112351893B (en) Method for finishing large-size building board
JP6211782B2 (en) Metal decorative material and manufacturing method thereof
RU177313U1 (en) DECORATED FACING PANEL
EP0165680B1 (en) A method of producing a strip with an embossed finish
EP2943621A1 (en) Process for producing composite finishing panels and panel obtained with this process
CN207484895U (en) A kind of floor that two to three kinds of decorative patterns or pattern is presented
US20050205567A1 (en) Decorative strip for kitchen appliances
KR102245316B1 (en) heat-laminated CPP film for exterior decoration and its manufacturing method
KR101402726B1 (en) Panel for decoration
KR20060117625A (en) Method for manufacturing steel plate laminated with fabric through automation
CN205531144U (en) Light sense discolours and decorates ecological plate

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 14774238

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 14774238

Country of ref document: EP

Kind code of ref document: A1