GB2241191A

GB2241191A - Forming decorative panels

Info

Publication number: GB2241191A
Application number: GB9004049A
Authority: GB
Inventors: David Kane
Original assignee: Individual
Current assignee: Individual
Priority date: 1990-02-22
Filing date: 1990-02-22
Publication date: 1991-08-28
Anticipated expiration: 2010-02-22
Also published as: GB9004049D0; GB2241191B

Abstract

A panel has a decorative beading cast from resin directly on to the edge of the panel. It is formed by providing a peripheral mould for the beading and locating a board (29) on the mould and at a level lower than the outer rim (23) of the mould. A resin is then introduced to fill the mould and engage the edge of the board which forms the panel. <IMAGE>

Description

FORMING DECORATIVE PANELS This invention relates to a method of forming a decorative panel of the type having a beading around the periphery thereof.

Conventionally, such panels are formed by attaching preformed moulded beading, typically of wood or plastics material, to a board or the like. This involves accurately cutting the beading to size and mitring the corners to give a precise fit. The beading is then attached by pinning to the board, optionally with the use of glue. There are several problems with this arrangement. Firstly, any inaccuracy in cutting, and particularly in mitring, may result in gaps which require to be filled. Secondly, pinning involves the risk of splitting the beading and in damage to the beading in driving the pin into place. Thirdly, the process is labour intensive and therefore costly.

Accordingly, the present invention provides a method of forming a panel having a decorative beading around at least part of the periphery thereof, comprising: (a) forming a mould for the beading, said mould having an inner edge at a first level corresponding to the front face of the panel and an outer edge at a second, higher, level, preferably corresponding to the rear face of the panel; (b) introducing a curable resin into the mould up to said first level.

(c) before the resin has cured, placing on said mould in contact with said resin a board dimensioned and arranged such that a substantially uniform gap exists around the periphery thereof between the outer edge of the board and the edge of the mould; (d) filling said gap with curable resin up to said second level; (e) allowing the resin to cure; and (f) separating the panel from the mould.

Preferably, the mould is such as to form beading around the complete periphery of the panel. The beading may simulate wooden mouldings or may be formed in a shape not readily achievable in wood. The resin may be such as to form a rigid or a flexible moulding, for example an acrylic resin. The resin may be self-curing, for example by the addition of a hardener, or may be cured by, for example, the application of ultra-violet light.

The board may be of chipboard, plywood, solid wood, plastics or even metal.

The mould used is preferably formed of a silicone rubber, for example by casting the rubber over a fabricated template.

The method of the invention provides a simple way of forming decorative panels which avoids the problems associated with pinning or beading and which enables a wide range of configurations to be formed.

Reference is made to the drawings, in which: Figure 1 is a view of a door having attached thereto three decorative panels formed in accordance with the invention; Figure 2 illustrates the formation of a mould for use in the method of the invention; Figure 3 illustrates the use of the mould in the method of the invention; and Figure 4 shows a section through a completed panel.

The door 1 shown in Figure 1 has three decorative panels 2, 3, 4, formed in accordance with the method of the invention. Each panel has a raised beading around its periphery and is attached to the door 1 by pinning and/or gluing.

In a method according to a preferred embodiment of the invention, a pattern 20 (Figure 2) is fabricated for each panel by attaching pre-formed beading 21 to a board 22. To form the curved portions, for example as shown in the panels in Figure 1, flexible beading may be used, if necessary formed by casting a flexible resin material using a straight length of the beading as a pattern.

A continuous mould is then formed around the pattern by attaching wooden strips 23 to the board 22 around the outside of the beading 21 with a small gap between the strips 23 and the beading 21. Wooden pieces 24, whose thickness is the same as the board which is eventually to be the basis of the decorative panels, are attached to the board 22 abutting the inner edge of the beading 21. Further pieces of wood 25 are placed on the pieces 24 with thin fillets 26 of wood between them. The upper faces of the pieces 23 and 25 all lie in the same plane. The pieces of wood 24, 25 and 26 are all secured together and to the base board 22.

A silicone rubber moulding compound of a type commonly used for casting purposes, is poured into the mould over the beading up to the level of the upper faces of the pieces of wood 23 and 25. The resin is allowed to cure and a further board 27 (Figure 3) is then fastened to the upper faces of the pieces 23 and 25. The first base board 22, and with it the beading 21 and the pieces of wood 24 and 26, is removed, leaving the arrangement illustrated in Figure 3. This is the mould used to form the panels in accordance with the method of the invention.

A self-hardening resin compound, for example an acrylic compound, is introduced into the mould up to the level of the inner edge 28. A board 29, forming the basis of the eventual panel, is then placed on the mould in contact with the resin therein. The board 29 has a shape generally corresponding with the external edge of the beading mould, but of slightly smaller overall dimensions so that a gap is left around the periphery of the board 29. It will be seen from Figure 3 that the gap 30 left by the fillet 26 serves to ensure that the board 29 rests on the edge 28 of the mould. Because of the slight elasticity of the silicone rubber mould, the weight of the board 29 ensures good contact with the uncured resin in the mould. Further resin is then poured into the mould up to the level of the rear face of the board 29. The resin is allowed to harden before the panel is detached from the mould.

Figure 4 shows a section through a decorative panel after removal from the mould. The beading is moulded onto the periphery of the board and requires no other means of attachment. The decorative panel can then be attached to the door or other surface, for example by pinning through the board 29 without risk of damage to the beading. The beading may be self-coloured to achieve the desired finish, or it may be painted together with the board.

Claims

1. A method of forming a panel having a decorative beading around at least part of the periphery thereof, comprising: (a) forming a mould for the beading, said mould having an inner edge at a first level corresponding to the front face of the panel and an outer edge at a second, higher level; (b) placing on said inner edge of said mould a board dimensioned and arranged such that a substantially uniform gap exists around the periphery thereof between the outer edge of the board and the edge of the mould; (c) introducing a curable resin into the mould up to said first level; (d) allowing the resin to cure; and (e) separating the panel from the mould.

2. A method according to Claim 1, wherein the mould is formed such that the second level corresponds to the rear face of the panel.

3. A method according to Claim 1 or 2, wherein the mould is such as to form beading around the complete periphery of the panel.

4. A method according to Claim 1, 2 or 3, wherein the resin is an acrylic resin.

5. A method according to Claim 1, 2 or 3, wherein the resin is a UV-curable resin, and step (d) comprises exposing the resin to UV light.

6. A method according to any preceding claim, which comprises forming the mould by casting silicone rubber over a fabricated template.

7. A method of forming a panel, substantially as described with reference to the drawings.

8. A panel having a decorative beading around at least part of the periphery thereof, wherein the beading is formed from a resin cast on to the edge of the panel.

9. A decorative panel, substantially as described with reference to, or as shown in, Figure 1 or Figure 4 of the drawings.