AU2019271977A1

AU2019271977A1 - Enhanced tactile and auditory properties from hard materials

Info

Publication number: AU2019271977A1
Application number: AU2019271977A
Authority: AU
Inventors: David Price
Original assignee: Depco TRH Pty Ltd
Current assignee: Depco TRH Pty Ltd
Priority date: 2018-11-29
Filing date: 2019-11-27
Publication date: 2020-06-18

Abstract

Abstract The invention provides a layered sheet, panel, or tile, including a decorative hard layer having a first surface and an opposite facing second surface, the first surface including a decorative surface finish; and a compressible material layer adhered to and 5 overlying the second surface. Figure 1

Description

Enhanced tactile and auditory properties from hard materials

Field of the invention

The invention relates to multilayered structures and/or layered panels exhibiting improved tactile and/or auditory properties such as when used in the manufacture of a 5 wall, room divider, benchtops, cabinetry or furniture.

Background of the invention

Tactile sensation refers to the perception from touch. A widely used decorative hard material is high pressure laminate (HPL). HPL is considered to be one of the most durable decorative surface materials, produced primarily from paper and thermosetting 10 resins. The uppermost surface is the decorative surface and the uppermost resin is usually melamine formaldehyde resin. Generally, the high pressure laminate is adhered to a substrate such as particleboard or medium density fibreboard (MDF) using an adhesive. The particleboard or MDF substrate provided a stable and economical foundation for the thin and hard HPL material. HPL is usually available in sheet format 15 of thicknesses between 0.4mm and 1.2mm although other thicknesses are available. A more recent and similar product is continuous pressure laminate (CPL) usually available in similar thicknesses to HPL, however available in both sheet and roll format. Laminates with a melamine formaldehyde resin surface are available with special performance characteristics such as chemical, fire and wear resistance and also with 20 any number of surface textures. Still, thermosetting resin surfaces based on melamine formaldehyde resin are described as cold to the feel. Another way to describe this coldness would be inanimate, lifeless and this sensation does not change when attached to a hard substrate such as particleboard or MDF.

Auditory sensation in human beings provides the possibility to enjoy sounds. The 25 physical stimulus for auditory sensation is sound waves (airborne noise). The ear is the receptor of auditory sensation, and the frequency and intensity of sound determines the level of enjoyment or discomfort. A typical wooden or metal frame wall with plasterboard attached is susceptible to a drumming effect when the plasterboard is tapped. The term drumming most likely stems from the effect being very similar to noise made when

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2019271977 27 Nov 2019 tapping a drum. The drum itself is in essence a skin (hide) drawn taut on a frame.

Plasterboard attached to the wall frame enables a similar effect.

One approach to reduce airborne noise, measured as an increase in the Rw (weighted sound reduction index) is to apply additional layers of plasterboard over an existing plasterboard, for example Boral NeighbourZone™. The added layers of plasterboard, sometimes referred to as drywall, provide an additional barrier to sound, however this approach reduces the internal living space of a room, and the plasterboard still requires finishing, usually by sealing the joints and painting. The use of insulation material such glass wool Pink Batts® to fill wall cavities is a common activity to reduce thermal transmission through the wall. However, insulation designed to prevent heating/cooling of dwellings is often not well suited for sound proofing. Special grades of insulating materials such as Pink® Soundbreak® are more expensive than a standard Pink Batts® product but do claim to absorb airborne noise as well as provide thermal properties. Furthermore, installation can be difficult as it may require removal of wall cladding or the drilling of holes so that insulating material can be fed into the wall cavity.

An object of the present invention is to address or ameliorate at least one of the shortcomings of the prior art.

Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any ’0 jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and/or combined with other pieces of prior art by a skilled person in the art.

Summary of the invention

In a first aspect of the invention, there is provided a layered sheet, panel, or tile, 25 including:

a decorative hard layer having a first surface and an opposite facing second surface, the first surface including a decorative surface finish; and a compressible material layer adhered to and overlying the second surface.

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In an embodiment of there is provided the layered sheet, panel, or tile when used as, or in the manufacture of, a wall, room divider, benchtop, cabinetry or furniture.

In an embodiment, the second surface of the decorative hard layer is a planar surface that is substantially covered by the compressible material layer. Preferably, the 5 entire second surface is covered by the compressible material layer.

In an embodiment, the sheet, panel, or tile further includes a second hard layer; wherein the compressible material layer is located between the first hard layer and the second hard layer, and arranged so that the first hard layer and the second hard layer are spaced apart by at least the compressible material layer.

In forms of the above embodiment, the second hard layer includes a first surface and an opposite facing second surface, and the first surface includes a decorative surface finish; and wherein the compressible material layer is adhered to and overlies the second surface.

In an embodiment, the second surface of the second hard layer is a planar 15 surface that is substantially covered by the compressible material layer. Preferably, the entire second surface is covered by the compressible material layer.

In various embodiments, the compressible material is adhered to the second surface of the decorative hard layer and/or the second surface of the second hard layer with an adhesive.

In various embodiments, the decorative hard layer and/or the second hard layer are formed of a structural material having a Young’s modulus of 2 GPa or greater. Preferably, the Young’s modulus of the hard layer is 2.5 GPa or greater. More preferably, the Young’s modulus of the hard layer is 3 GPa or greater. Most preferably, the Young’s modulus of the hard layer is 3.5 GPa or greater.

In various embodiments, the second hard layer or layers are formed of a structural material selected from the group consisting of: metal, wood, glass, plastic, concrete, brick, ceramic, particleboard, oriented strandboard, plasterboard or combinations thereof.

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In an embodiment, the compressible material is formed of a material having a Young’s modulus of 0.1 GPa or less. Preferably, the Young’s modulus of the compressible material is 0.075 GPa or less. More preferably, the Young’s modulus of the compressible material is 0.05 GPa or less. Even more preferably, the Young’s 5 modulus of the compressible material is 0.025 GPa or less. Most preferably, the Young’s modulus of the compressible material is 0.01 GPa or less. Alternatively, or additionally, it is preferred that the compressible material has a Young’s modulus of at least 0.001 GPa.

In an embodiment, the compressible material layer is formed of a material I0 selected from the group consisting of: polymers, polymer foams, natural or synthetic rubbers. Preferably, the compressible material is an expanded polymer. Most preferably, the compressible material is expanded polystyrene.

In an embodiment, the compressible material layer is a composite material including a matrix phase of the compressible material with one or more additive 15 materials incorporated therein. In preferred forms, the additive materials are selected from fibres and/or particles. The additive materials may provide a range of benefits including enhanced material properties, such as resilience, stability, and/or product life.

In embodiment of the first or second aspects, the compressible material has been chemically treated, for example, with stabilisers, bactericide, fungicides, pesticides, fire >0 or flame retardants, volatile organic compound (VOC) absorbers (such as urea compounds which can absorb a range of VOCs such as formaldehyde) etc.

In embodiments of the first or second aspects, the one or more compressible material layers have a thickness of from about 2 mm up to about 20 mm. Preferably, the thickness is from about 3 mm. More preferably, the thickness is from about 4 mm. 25 Alternatively or additionally, the thickness is up to about 15 mm. More preferably, the thickness is up to about 10 mm. Most preferably, the thickness is up to about 8 mm.

In preferred forms of the invention, the decorative hard layer is a high pressure laminate (HPL) or a continuous pressure laminate (CPL) layer; the compressible material layer is an expanded polystyrene layer; and in embodiments which include the

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2019271977 27 Nov 2019 second hard layer, the second hard layer is particleboard, oriented strand board (OSB) or plasterboard or combinations thereof.

In a second aspect of the invention, there is provided a method of construction, including:

forming a multilayered structural sheet or panel including:

a first hard layer, a second hard layer, one or more compressible material layers located between the first hard layer and the second hard layer, and arranged so that the first hard layer and the 10 second hard layer are spaced apart by at least the one or more compressible material layers.

In an embodiment, the step of forming the multilayered structure includes:

adhering the one or more compressible material layers to at least a portion of a surface of the second hard layer; and adhering the first hard layer to the multilayered structure so that the first hard layer and the second hard layer are spaced apart by at least the one or more compressible material layers.

In one form of the above embodiment, the step of adhering the first hard layer to the multilayered structure includes nailing and/or stapling and/or screwing the first hard 20 layer to the multilayered structure, wherein nails and/or staples and/or screws penetrate the first hard layer, the one or more compressible material layers, and at least a portion of the second hard layer.

In an embodiment, the step of forming the multilayered structure includes:

arranging a layered sheet, panel, or tile including the first hard layer and 25 the one or more compressible material layers so that a surface of the one or more compressible material layers is in contact with a surface of the second hard layer; and

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2019271977 27 Nov 2019 adhering the layered sheet, panel, or tile to the second hard layer.

In one form of the above embodiment, the step of the layered sheet, panel, or tile to the multilayered structure includes nailing and/or stapling and/or screwing the first hard layer to the multilayered structure, wherein nails and/or staples and/or screws 5 penetrate the first hard layer, the one or more compressible material layers, and at least a portion of the second hard layer.

In an embodiment, the first hard layer has a planar layer surface facing towards the second hard layer, and the planar layer surface is substantially covered by the compressible material layer. Preferably, the entire planar layer surface is covered by the 10 compressible material layer.

In an embodiment, the first hard layer has a decorative exposed surface. In one form of this embodiment, the second layer has a decorative exposed surface. In such cases, it is preferred that the multilayered structural component is a panel or a tile.

In an embodiment, the second hard layer has a planar layer surface facing 15 towards the first hard layer, and the planar layer surface is substantially covered by the compressible material layer. Preferably, the entire planar layer surface is covered by the compressible material layer.

In an embodiment, the second hard layer is a wall frame. In one form of this embodiment, the multilayered structural component is a wall cavity and cladding. In this 20 form, the first hard layer is a cladding material and the second hard layer is the wall frame (e.g. formed from wall studs and/or noggins). In other forms of this embodiment, the second hard layer may be a wall frame formed from brick or concrete etc.

In an embodiment, the first hard layer and the second hard layer are each formed of a structural material having a Young’s modulus of 2 GPa or greater. Preferably, the 25 Young’s modulus of the first hard layer and/or the second hard layer is 2.5 GPa or greater. More preferably, the Young’s modulus of the first hard layer and/or the second hard layer is 3 GPa or greater. Most preferably, the Young’s modulus of the first hard layer and/or the second hard layer is 3.5 GPa or greater.

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In an embodiment, the first hard layer and the second hard layer are each formed of a structural material independently selected from the group consisting of: metal, wood, glass, plastic, concrete, brick, ceramic, particleboard, oriented strandboard, plasterboard or combinations thereof.

In a third aspect of the invention, there is provided a method of forming a layered sheet, panel, or tile, including:

providing a decorative hard layer having a first surface and an opposite facing second surface, the first surface including a decorative surface finish; and applying a compressible material layer to the second surface.

In an embodiment, the second surface of the decorative hard layer is a planar surface that is substantially covered by the compressible material layer. Preferably, the entire second surface is covered by the compressible material layer.

In an embodiment, the layered sheet, panel, or tile includes a second hard layer having a first surface and an opposite facing second surface, the first surface of the 15 second hard layer including a decorative surface finish; and wherein the compressible material layer is applied to and overlies the second surface of the second hard layer.

In an embodiment, the second surface of the second hard layer is a planar surface that is substantially covered by the compressible material layer. Preferably, the entire second surface is covered by the compressible material layer.

In an embodiment, the step of applying the compressible material layer to the second surface of the first hard layer and/or the second surface of the second hard layer includes attaching the compressible material layer to the respective second surface. Preferably, the step of attaching includes adhering the compressible material layer to the respective second surface with an adhesive.

In an embodiment, the second surface of the first hard layer and/or the second surface is substantially covered by the compressible material layer. Preferably, the entire second surface of the first hard layer and/or the second surface is covered by the compressible material layer.

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In various embodiments, the decorative hard layer and/or the second hard layer are formed of a structural material having a Young’s modulus of 2 GPa or greater.

Preferably, the Young’s modulus of the hard layer is 2.5 GPa or greater. More preferably, the Young’s modulus of the hard layer is 3 GPa or greater. Most preferably, the Young’s modulus of the hard layer is 3.5 GPa or greater.

In various embodiments, the decorative hard layer and/or the second hard layer are formed of a structural material selected from the group consisting of: metal, wood, glass, plastic, concrete, brick, ceramic, or combinations thereof.

In embodiments of the second or third aspects, the compressible material is 10 formed of a material having a Young’s modulus of 0.1 GPa or less. Preferably, the Young’s modulus of the compressible material is 0.075 GPa or less. More preferably, the Young’s modulus of the compressible material is 0.05 GPa or less. Even more preferably, the Young’s modulus of the compressible material is 0.025 GPa or less. Most preferably, the Young’s modulus of the compressible material is 0.01 GPa or less.

Alternatively, or additionally, it is preferred that the compressible material has a Young’s modulus of at least 0.001 GPa.

In embodiments of the second or third aspects, the compressible material layer is formed of a material selected from the group consisting of: polymers, polymer foams, or natural or synthetic rubbers. Preferably, the compressible material is an expanded ’0 polymer. Most preferably, the compressible material is expanded polystyrene.

In embodiments of the second or third aspects, the compressible material layer is a composite material including a matrix phase of the compressible material with one or more additive materials incorporated therein. In preferred forms, the additive materials are selected from chemicals, fibres, and/or particles. The additive materials may provide 25 a range of benefits including enhanced material properties (e.g. fire resistance, product life, etc.)

In embodiments of the second or third aspects, the one or more compressible material layers have a thickness of from about 2 mm up to about 20 mm. Preferably, the thickness is from about 3 mm. More preferably, the thickness is from about 4 mm.

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Alternatively or additionally, the thickness is up to about 15 mm. More preferably, the thickness is up to about 10 mm. Most preferably, the thickness is up to about 8 mm.

In a fourth aspect of the invention, there is provided a multilayered component of one or more hard layers and one or more layers of a compressible material to provide 5 enhanced tactile and auditory sensations when used to manufacture a wall, room divider, benchtop, cabinetry or furniture.

In a fifth aspect of the invention, there is provided a multilayered component of one or more hard layers and one or more layers of a compressible material used to manufacture a wall, room divider, benchtop, cabinetry or furniture having an enhanced IO auditory and tactile sensation by affixing a compressible material between a hard substrate and a hard decorative material.

In a sixth aspect of the invention, there is provided a multilayered component of one or more hard layers and one or more layers of a compressible material where the compressible material is expanded polystyrene.

In a seventh aspect of the invention, there is provided a multilayered component of one or more hard layers and one or more layers of a compressible material where the hard layer is one or more of plasterboard, oriented strand board, or particleboard.

In an eighth aspect of the invention, there is provided a multilayered component of one or more hard layers and one or more layers of a compressible material where the 20 hard decorative material is one or more of high pressure laminate, or continuous pressure laminate.

In a ninth aspect of the invention, there is provided a multilayered component of one or more hard layers and one or more layers of a compressible material where one or more layers include antimicrobial, and/or antibacterial, and/or antifungal, and/or 25 antimould, and/or fire retardant features, and/or VOC absorbents (such as urea compounds).

In a tenth aspect of the invention, there is provided a method of construction, including forming a multilayered component with one or more hard layers and one or more layers of a compressible material

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In an eleventh aspect of the invention, there is provided a method of construction, including forming a multilayered component with one or more hard layers and one or more layers of a compressible material where the compressible material is between a hard substrate and a decorative hard material.

Embodiments of the fourth to eleventh aspects of the invention can incorporate features of the embodiments disclosed in relation to the first, second, and third aspects of the invention.

In one or more embodiments of any one of the above mentioned aspects, the first layer hard layer has a layer thickness of 2mm or less; and preferably of from about 10 0.2 mm to about 2 mm.

In one or more embodiments, the sheet, panel, or tile has an Rw value of 35 or greater. Preferably, the Rw value is 40 or greater. More preferably, the Rw value is 50 or greater.

Further aspects of the present invention and further embodiments of the aspects 15 described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings.

Brief description of the drawings

Figure 1: Photograph of a high pressure laminate laminated with expanded polystyrene panel according to an embodiment of the invention.

Figures 2 & 3: Photograph of a panel according to an embodiment of the invention.

Figure 4: Photograph of a composite panel according to an embodiment of the invention showing expanded polystyrene between the OSB panel and the plasterboard, and between the plasterboard and the decorative high pressure laminate.

.Figure 5: Photograph of a panel according to an embodiment of the invention including 33mm particleboard laminated with expanded polystyrene and decorative high pressure laminate.

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Figures 6 & 7: Photograph of a wall frame showing expanded polystyrene attached to the base plate, studs and noggins.

Figure 8: Photograph of a wall section showing plasterboard attached to the wall frame and expanded polystyrene attached to the plasterboard.

Figure 9: Photograph of a wall section showing expanded polystyrene attached to the wall frame, and between the plasterboard and the decorative high pressure laminate

Figures 10 & 11: Photographs of panels according to an embodiment of the invention, including joint covering elements between adjacent panels.

IO Detailed description of the embodiments

The invention relates to a multilayered structural component, a layered sheet, panel, or tile, as well as methods of forming multilayered structural components and/or layered panel and/or tiles. The multilayered structural component or panel can for example be a component of a wall, a room divider, benchtop, cabinetry, furniture.

The multilayered structural component or layered sheet/panel/tile includes a compressible material layer arranged or laminated between two hard layers which arrangement dampens sounds transmitted therethrough and to provide an enhanced tactile sensation in comparison with the same multilayered structural component or layered panel/tile absent the compressible material layer. The layered sheet/panel/tile (generally referred to as a panel below) includes at least one decorative hard material layer with the compressible material adhered thereto. The panel can be used as a construction element in which case it can be applied to a hard surface such that the compressible material is located between two hard surfaces. As above, an advantage of this arrangement is that it can dampen sounds and provide enhanced tactile sensation.

Tactile sensation refers to perception from touch. In addition to providing a mechanism to influence the auditory sensation, the compressible material also provides an influence to tactile sensation. The compressible material combined with a decorative hard material has a small “give” (compression) when pressure is applied. For example, a 4mm expanded polystyrene (EPS) material may be compressed with light pressure to

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2019271977 27 Nov 2019 less than 50% of its original thickness. EPS in greater thicknesses would provide greater amount of “give” (compress) when pressure is applied. When applied to a hard material structure such as a concrete or brick wall, a decorative hard material in combination with a compressible material can be made to feel less inanimate through a 5 perception of movement due to the ability of the compressible material to compress and rebound. The compressible material may be applied directly to a concrete or brick wall and a decorative hard material adhered to the wall/compressible material, or the compressible material may be attached to the decorative hard material and the resulting combination of compressible material and the decorative hard material adhered to the 10 wall.

Various combinations, including multiple layers of compressible material between multiple base hard material panels and between the base panel and a decorative hard material are contemplated. Such combinations can be used to prepare walls, room dividers, benchtops, cabinetry, or furniture with decorative hard materials in combination 15 with the compressible material to achieve the tactile effect and/or desired sound dampening.

The range of combinations is broad and in a non-limiting disclosure, includes: (1) a simple application of compressible material adhered to the frame and compressible material adhered to the hard plasterboard material (see Figure 8), and overlaid with a ’0 decorative high pressure laminate to make a wall with enhanced auditory and enhanced tactile sensations (see Figure 9). Another example (2) is the combination of oriented strand board, plasterboard, high pressure laminate and interlaid compressible material (see Figure 4). Still a further example (3) may be applied to a manufacturing a benchtop where the compressible material is applied to a 33mm particleboard substrate 25 and the decorative HPL material is adhered to the compressible material (see Figure 5).

In various embodiments, the compressible material is attached to a decorative hard material panel, and in certain forms is laminated between the decorative hard material panel and a second hard material panel formed from a substrate such as 30 plasterboard, plywood, or a wood panel such as particleboard or oriented strand board (OSB). The compressible material layer can include a substrate/support/backing layer,

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2019271977 27 Nov 2019 in which case the compressible material layer can be attached or adhered directly to the first or second hard layers via the substrate/support/backing layer.

In addition to sound dampening the frame material with a compressible material, when a decorative hard material, especially thin decorative hard materials such as high 5 pressure laminate (HPL), is to be affixed to another hard material for example plasterboard or a wood panel, an additional compressible material layer (which may be the same or different as the compressible material layer attached to the frame) can be affixed to be between the back of the HPL and the underlying hard material. The combination of multiple layers of compressible material sandwiched between multiple 10 hard layers further enhances the tactile sensation and/or sound dampening.

The invention will now be described below with reference to the specific embodiments illustrated in the Figures.

Figure 1 illustrates an embodiment of the invention in the form of a panel 100. This panel is formed by laminating a compressible material such as expanded 15 polystyrene (EPS) to a high pressure laminate (HPL) and adhering the EPS/HPL composite to a hard material substrate such as plasterboard, particleboard or oriented strand board. To prevent air pockets forming it is preferable that the compressible material is attached to the hard material substrate and the hard decorative material by applying the adhesive in an all-over manner.

>0 In more detail, the panel 100 includes a hard layer 101, in this case the hard layer 101 is a high pressure laminate. The hard layer 101 of the panel 100 has a first surface 102 and an opposite facing second surface (not shown). The first surface 102 has a decorative finish. In the present example, the first surface 102 is a wood grain texture.

The compressible material layer 104 is adhered to the second surface of the panel 100. As previously discussed, the compressible material layer 104 includes a support layer for retaining the compressible material. In this case, the compressible material layer 104 is adhered to the second surface of the panel via adhesion of the support layer to the second surface of the panel 100.

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An example of a compressible material to enhance tactile and auditory sensations when placed between two or more hard materials is expanded polystyrene (EPS).

In the present example, the compressible material layer 108 is Neopor® GPS, an 5 expanded polystyrene (EPS) layer which includes graphite particles dispersed therethrough and a flame retardant additive. The expanded polystyrene layer is arranged on a support layer of a backing material (best shown as item 900 in Figure 8 & 9).

The support layer can be formed from a variety of different materials including I0 woven and non-woven materials. Such materials include: Kraft paper, fabrics, metal foil (e.g. aluminium foil which can additionally provide heat reflection), polymer film, cellulose film, a Velcro® type material layer, or a glass nonwoven material.

The compressible material layer can be a composite layer (in the case of the present example includes a nonwoven backing material) and may be treated with one or 15 more chemical reagents. By way of example, the compressible material layer can contain or be treated with antibacterial, antimicrobial, antifungal, anti-mould or fire retardant additives. The antibacterial, antimicrobial, antifungal, anti-mould or fire retardant additives may be incorporated into the support layer. The support layer and/or the compressible material layer material can be treated with a coating to adsorb fugitive >0 volatile organic compounds, for example but not limited to a coating containing urea.

Without limiting the choice of materials used to form the decorative surface of the hard material layer, such materials include: high pressure laminates (HPL), continuous pressure laminates (CPL), laminated veneer sheeting or the like.

Figure 2 and Figure 3 are photographs of another embodiment of a panel 25 according to aspects of the invention. Figure 2 shows a panel 200 that includes a compressible material (in this case expanded polystyrene with a backing layer) retained between two decorative hard panels (only the first of which is shown). Figure 3 is a close up photograph of the panel 200 of Figure 2 showing the multilayered structure. The panel 200 has a decorative first outermost hard layer 302 exhibiting a woodgrain 30 like decorative finish. The panel 200 includes compressible layer 304 sandwiched

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2019271977 27 Nov 2019 between the first hard layer 302 and a second outermost hard layer 306 which is also decorative (although this cannot be seen from the photograph). The two outermost decorative faces of a panel may have the same decorative aspect or a different decorative aspect, for example one side may depict a wood-like pattern (as per layer

302) whilst the other side may depict a stone-like pattern.

Furthermore, in the embodiments illustrated in Figures 2 and 3, the compressible material layer is not adhered to corresponding surfaces of the decorative hard material layers. Instead, the compressible material layer is held in place by compressive forces applied by perimeter railings 202 and 204.

Figure 4 is a photograph of a composite panel 400 according to an embodiment of the invention. In this embodiment, a hard material panel 402 such as oriented strand board (OSB) is used together with plasterboard 404 as base materials, which may for example be attached to a wall frame, whereby a first compressible material layer 406 is located between the OSB 402 and the plasterboard 404, and a second compressible material layer 408 also between the plasterboard 404 and a decorative HPL panel 410.

Figure 5 is a photograph of a composite panel 500 according to a further embodiment of the invention that may be used, for example, as a benchtop. In this embodiment, a compressible material 502 is applied to a 33mm particleboard substrate 504 and the decorative HPL material 506 is adhered to the compressible material 504.

>0 Figures 6 to 9 illustrate embodiments in which a panel, such as panel 100, is applied during the construction of a wall. By way of example, this can be achieved by laminating a compressible material such as expanded polystyrene (EPS) to a high pressure laminate (HPL) and adhering the EPS/HPL composite to a hard material substrate such as plasterboard. To prevent air pockets forming it is preferable that the 25 compressible material is attached to the hard material substrate and the hard decorative material by applying the adhesive in an all-over manner.

In one particular form, when constructing a wall using a product of the invention, the frame material may also have a compressible material applied. This combination of compressible material on the frame and between the two hard materials further 30 enhances at least the auditory sensation.

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The inventor has found that use of a panel, such as panel 100 of Figure 1 in the construction of a wall can provide a wall with superior tactile sensation and/or sound dampening. In particular, the use of multiple layers of the compressible material between multiple hard layers further enhances these properties.

In the embodiments illustrated in Figures 6 to 9, panel 100 is applied to the external cladding of a wall. The wall includes a wall frame 600 that is formed from interconnected studs 602 and noggins 604 on top of a base 606. The studs 602, noggins 604, and base 606 form a hard layer with a contiguous planar surface. An intermediate layer of a compressible material 608 is attached to this contiguous planar I0 surface in such a manner that the contiguous planar surface is entirely covered by the intermediate layer compressible material 608. A plasterboard layer 800 is then applied to the surface of this intermediate layer of compressible material 608. Figure 6 shows a stage where only part of the plasterboard (left side) is covered with compressible material 900. Panel 100 is then affixed over the surface of the plasterboard layer.

Figure 9 shows the layered structure of the wall of Figures 6 to 8. In Figure 9, the wall frame 600 includes the intermediate compressible material layer 608 on the surface of the wall cavity, and a cladding 800 applied over this intermediate compressible material layer 608 to form the wall. The panel 100 of Figure 1 is then applied over the surface of the cladding 800 such that the compressible material layer >0 104 of the panel 100 contacts the surface of the cladding and spaces the hard decorative layer 101 from the cladding layer 800 such that the decorative surface 102 of the hard decorative layer 101 faces outwards from the wall.

The inventor has found that this particular layered arrangement (e.g. providing a wall structure including a compressible material located between the wall frame and the 25 plasterboard, and then applying a panel 100 to the surface of the plaster board) further reduces sound transmission through the wall and/or provides improved tactile sensation in that the wall exhibits a “give” when pressure is applied.

The use of decorative hard material in panel or sheet format when used in sheet or tile format may for aesthetic and/or hygiene reasons require a grouting material or a 30 covering element when the sheets are not abutted. Figure 10 and Figure 11 provide an example illustrating the use of a covering element 1000 or 1100.

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A non-limiting list of other embodiments of the invention includes: room dividers, benchtops, cabinetry, or furniture.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features 5 mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims

1. A layered sheet, panel, or tile, including:

a decorative hard layer having a first surface and an opposite facing second surface, the first surface including a decorative surface finish; and

2. The layered sheet, panel, or tile of claim 1, wherein the compressible material is adhered to the second surface with an adhesive.

3. The layered sheet, panel, or tile of claim 1 or 2, wherein the second surface is substantially covered by the compressible material layer.

IO

4. The layered sheet, panel, or tile of any one of claims 1 to 3, wherein the decorative hard layer is formed of a structural material having a Young’s modulus of 2 GPa or greater.

5 15. A multilayered component of one or more hard layers and one or more layers of a compressible material where the compressible material is expanded polystyrene.

5 layers.

5. The layered sheet, panel, or tile of any one of claims 1 to 4, wherein the hard layer is formed of a structural material selected from the group consisting of: metal, 15 wood, glass, plastic, concrete, brick, ceramic, particleboard, oriented strandboard, plasterboard or combinations thereof.

5 a compressible material layer adhered to and overlying the second surface.

6. The layered panel of any one of claims 1 to 5, wherein the compressible material is formed of a material having a Young’s modulus of 0.1 GPa or less.

7. The layered panel of any one of claims 1 to 6, wherein the compressible material 20 layer is formed of a material selected from the group consisting of: polymers, polymer foams, natural or synthetic rubbers.

8. The layered panel of claim 7, wherein the compressible material is expanded polystyrene.

9. A method of construction, including:

25 forming a multilayered structural component including:

a first hard layer,

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2019271977 27 Nov 2019 a second hard layer, one or more compressible material layers located between the first hard layer and the second hard layer, and arranged so that the first hard layer and the second hard layer are spaced apart by at least the one or more compressible material

10. The method of claim 9, wherein the step of forming the multilayered structure includes:

adhering the one or more compressible material layers to at least a portion of a surface of the second hard layer; and

IO adhering the first hard layer to the multilayered structure so that the first hard layer and the second hard layer are spaced apart by at least the one or more compressible material layers.

11. The method of claim 9, wherein the step of forming the multilayered structure includes:

12. A method of forming a layered sheet, panel, or tile, including:

20 providing a decorative hard layer having a first surface and an opposite facing second surface, the first surface including a decorative surface finish; and adhering a compressible material layer to the second surface.

13. A multilayered component of one or more hard layers and one or more layers of a compressible material to provide enhanced tactile and auditory sensations when used

25 to manufacture a wall, room divider, benchtop, cabinetry or furniture.

1002809392

2019271977 27 Nov 2019

14. A multilayered component of one or more hard layers and one or more layers of a compressible material used to manufacture a wall, room divider, benchtop, cabinetry or furniture having an enhanced auditory and tactile sensation by affixing a compressible material between a hard substrate and a hard decorative material.

15 antibacterial, and/or antifungal, and/or antimould, and/or fire retardant features, and/or VOC absorbent compounds.

15 arranging a layered sheet, panel, or tile including the first hard layer and the one or more compressible material layers so that a surface of the one or more compressible material layers is in contact with a surface of the second hard layer; and adhering the layered sheet, panel, or tile to the second hard layer.

16. A multilayered component of one or more hard layers and one or more layers of a compressible material where the hard layer is one or more of plasterboard, oriented strand board, or particleboard.

IO

17. A multilayered component of one or more hard layers and one or more layers of a compressible material where the hard decorative material is one or more of high pressure laminate, or continuous pressure laminate.

18. A multilayered component of one or more hard layers and one or more layers of a compressible material where one or more layers include antimicrobial, and/or

19. A method of construction, including forming a multilayered component with one or more hard layers and one or more layers of a compressible material.

20. A method of construction, including forming a multilayered component with one 20 or more hard layers and one or more layers of a compressible material where the compressible material is between a hard substrate and a decorative hard material.