GB2584110A

GB2584110A - Warp resistant covering

Info

Publication number: GB2584110A
Application number: GB1907168.7A
Authority: GB
Inventors: Quentin David Douglas Timothy; Fletcher Douglas Amos; Matthew Douglas Emil
Original assignee: Vtec Group Ltd
Current assignee: Vtec Group Ltd
Priority date: 2019-05-21
Filing date: 2019-05-21
Publication date: 2020-11-25
Also published as: GB201907168D0

Abstract

The warp resistant covering 10 comprises a decorative layer 12 having a first surface to be machined and a second surface opposing the first surface, and a rigid support layer 18 affixed to the second surface of the decorative layer at a first support surface of the rigid support layer. The rigid support surface may be affixed to a wall, door, or item of furniture, and abut the entirety of second surface of the decorative layer. A laminate layer may be affixed to a second surface of the rigid support layer. The layers may be affixed to each other using heat or pressure-curable adhesives 24, screws, nails, clamps, interlocking joints, or spacing elements. The layers may each comprise wood such as medium density fibreboard (MDF), metal, mineral such as gypsum, plasterboard, polymeric or composite material, Perspex (RTM), plastic, plywood, oriented strand board (OSB), foamed PVC, or aluminium based boards. The rigid support layer material may comprise a greater hardness, strength, flexural strength, or stiffness than the decorative layer material. The decorative layer may have a decoration 15 machined into the first surface. The covering may be a panel.

Description

WARP RESISTANT COVERING

Field of the Invention

The present invention relates to wall coverings, and particularly to coverings for, for example, walls, doors, desking and furniture, the coverings having a decoration machined into a primary surface thereof. The coverings may also be understood as "panels" or "panelling".

Background to the Invention

Currently, there are a number of efforts to produce decorative wall coverings, using techniques which are both time-efficient and cost-effective, while producing aesthetically pleasing pieces.

Common techniques involve, for example, the provision of feature walls by applying a decorative wall paper to the wall or applying a patterned or textured finish to a wall using, for example, Artex (trade mark) or a textured paint.

Such techniques invariably involve periods of time spent on-site, with varying quality of eventual products.

Some solutions are emerging to overcome some of the problems associated with such methods. An example of such a solution involves the application of pre-made wall panels to a wall. The pre-made panels typically carry some form of decorative two-dimensional design, and more recently, three-dimensional designs have been made possible.

This particular three-dimensional solution carries a number of drawbacks, most notably the inherent tendency of the panels to warp post production, during storage and prior to application. These problems are generally acknowledged in the industry, and various solutions have been attempted. The problems are particularly exacerbated when a finish, such as a paint or a varnish is applied to a machined surface.

It is therefore desirable to provide a solution which overcomes the disadvantages of the current solution of providing a wall panel to produce a three-dimensional decorative effect.

Particularly it is desirable to provide a solution which extends the lifetime of a decorative wall panel by mitigating or preventing effects of manufacture on the durability of the wall panel.

Summary of the Invention

In accordance with a first aspect of the present invention, there is provided a warp resistant decorative covering, the covering comprising: a decorative layer having a first surface to be machined, and a second surface opposing the first surface; and a rigid support layer affixed to the second surface of the decorative layer.

The covering is preferably one suitable for covering, for example, walls, doors, desking and furniture, the covering having a decoration to be machined into a primary surface thereof.

The term rigid will be understood to mean resistant to the effects of warping incurred by the decorative layer. A rigid support layer may be understood to be a material which is harder, stronger, flexurally stronger, and/or stiffer than the decorative layer. Such a material will be understood by the skilled addressee to be a material which is more resistant to deformation. Comparison of the "hardness", "strength", "flexural strength", and/or "stiffness" of the rigid support layer and the decorative layer will be understood to be taken following machining of the decorative layer, wherein said machining results in a reduced thickness of at least a portion of the decorative layer. In some examples therefore, the rigid support layer may be a similar or the same material as the decorative layer. In cases wherein the rigid support layer is the same material, the thickness of the rigid support layer may be the same or greater than that of the pre-machined decorative layer. Reduced thickness of at least a portion of the decorative layer caused by machining may confer a reduced hardness, strength, flexural strength and/or stiffness upon the decorative layer. In examples wherein the rigid support layer is the same material and the same thickness as the pre-machined decorative layer, the rigid support layer remains at the same thickness post-machining of the decorative layer and thus retains its hardness, strength, flexural strength and/or stiffness characteristic. In such an example, the resulting hardness, strength, flexural strength and/or stiffness of the decorative layer post-machining may be lower than the corresponding hardness, strength, flexural strength and/or stiffness of the rigid support layer. Examples will be appreciated wherein the rigid support layer is a different material to the decorative layer, and may comprise any suitable thickness to provide a hardness, strength, flexural strength and/or stiffness value sufficient for resisting deformation or warping of the decorative layer, thus retaining the decorative layer in an undeformed or unwarped state.

In the context of the present invention, the term "warp-resistant" and the term "deformation-resistant' will be understood by the skilled addressee as meaning the same thing, and may be used interchangeably. The term warping will preferably be understood in the context of the present invention as one or more edges or corners of a covering deviating from the principal plane of the covering by greater than 35 mm, and more preferably greater than 30 mm. A warp resistant cover in the context of the present invention preferably therefore comprises no edge or corner deviating from the principal plane of the covering by greater than 35 mm, and more preferably by 30 mm. Applications may exist wherein the term warping may be taken more narrowly to mean one or more edges or corners of a covering deviating from the principal plane of the covering by greater than 25 mm, and in most preferable cases greater than 20 mm. In such cases, the warp-resistant covering preferably comprises no edge or corner deviating from the principal plane of the covering by greater than 25 mm, with a more preferable warp-resistant covering having no edge or corner deviating from the principal plane of the covering by greater than 20 mm. Further applications may exist wherein the term warping may be taken more narrowly to mean one or more edges or corners of a covering deviating from the principal plane of the covering by greater than 15 mm, and in most preferable cases greater than 10 mm. In such cases, the warp-resistant covering preferably comprises no edge or corner deviating from the principal plane of the covering by greater than 15 mm, with a more preferable warp-resistant covering having no edge or corner deviating from the principal plane of the covering by greater than 10 mm. In most preferable embodiments, the warp-resistant covering preferably comprises no edge or corner deviating from the principal plane of the covering by greater than 5 mm, with a most preferable warp-resistant covering having no edge or corner deviating from the principal plane of the covering by greater than 2 mm Said "warping" may take place as a result of machining a decoration into a surface of the covering; applying and setting/curing of a decorative finish material to said surface; or a combination of these factors. In the case of a "dry" finish such as a polymer or varnish, said finish may result in a contraction of said surface when set/cured. As such said dry finish may cause warping in the direction of the surface to which the finish was applied (considered herein as a concave warping). In the case of a "wet" finish comprising water, such as a water-based paint, said finish may soak into the surface of the decorative layer material and cause swelling of said material. The swelling would be expected to cause warping away from the surface of the applied finish (considered herein as a convex warping). The present invention is intended to resist each form of said warping, preferably by minimising deviation of all corners of the covering from the principal plane of the covering.

The term "machined" will be understood by the skilled addressee in the context of the present invention to mean any form of subtractive manufacturing wherein a raw material is processed to produce a decorative finish, and to typically comprise one or more steps of removing a portion of the raw material. Said removal may for example be through etching, routing, milling, turning, drilling, carving, engraving, boring and/or sawing.

One technique for providing decorative wall coverings, which is the focus of the present patent application, involves machining a decorative pattern into a surface of a covering panel, and adhering or affixing the panel onto a wall.

Using this effective technique, amazing decorative pieces can be produced which are able to transform a space. The transformation and overall effect can be substantial, and the effect can be achieved with little time, labour and tooling costs. Currently, however, this technique comes with some disadvantages compared with other more established techniques. One primary disadvantage of the technique relates to the reduced thickness of the machined panel at some sections compared to others. The variable thickness of the panel carries a tendency for the machined panels to warp during or post machining, particularly in the direction of the machined surface. This tendency is relatively independent of machined-material type and has been observed in a large number of materials including wood, metal, mineral (e.g. gypsum) and polymer. Medium-density fibreboard (MDF) and plywood are two examples of a wood in which said warping has been observed.

Warping of said panels can cause a panel to no longer lie flush against a wall region which creates difficulties in aligning the panels making the job of installation harder, and reducing the likelihood of providing a pleasing appearance, which can reduce the aesthetic value of the product. Warping can also impart upon the fixture or fitting, which is arranged to affix the panel to the wall, a level of stress which acts to deteriorate said fixture or fitting which can reduce the lifetime of the panel product, and also potentially increase the chance that the product will fall from the wall, making the product hazardous. This potential effect of warping, applying tension to fixtures and fittings, can in extreme cases cause the fixings in of the rigid support layer to pull out, which can require replacement of the fixtures and fittings, or indeed an entire panel replacement. Damage can instead be incurred upon the underlying wall itself as a result of warping of the panel. In these cases, more considerable repair efforts are typically required. The associated time and labour costs to overcome these issues can act to diminish the benefits provided by this technique.

Possible solutions have been proposed, such as producing the panels from cheap raw materials, so as to reduce the cost of a replacement. Additional solutions have included the production of bespoke fixtures and fittings to mitigate the effect of the warping. Such fixtures and fittings may lengthen the lifetime of a product, but do not prevent deterioration of the aesthetic nature of the product through warping.

Preferably the rigid support layer may be affixed to a wall using an affixing means, which may be a fixing bracket. In preferable embodiments the fixing bracket comprises a first element which may be permanently affixed to the second surface of the rigid support layer, and a second element which may be permanently affixed to the wall. The first element and second element of the fixing bracket are then arranged to engage with one another to provide a secure affixing of the rigid support layer to the wall. In preferable embodiments the affixing means is hidden by the wall covering when affixed to the wall.

Preferably the rigid support layer abuts the second surface of the decorative layer. Embodiments may be preferable wherein maximum contact between the support layer and the second surface of the decorative layer provides the most effective warp resistance to the decorative layer. In such embodiments, the second surface of the decorative layer is substantially planar and is arranged to abut the rigid support layer across a maximum area of the second surface. In some preferable embodiments, the second surface is arranged to abut the rigid support layer across an entirety of the second surface.

Embodiments will be appreciated wherein maximum contact between the rigid support layer and the second surface of the decorative layer may not be required. In such embodiments, the rigid support layer may be formed from a frame-or lattice-structure.

Preferably the rigid support layer abuts the second surface of the decorative layer on a first support surface of the rigid support layer.

Preferably the warp resistant covering further comprises a laminate layer affixed to a second surface of the rigid support layer, the second surface of the rigid support layer opposing the first support surface.

Preferably the rigid support layer is affixed to the second surface of the decorative layer by an affixing means selected from the range: an adhesive; a screw; a nail; a clamp; an interlocking joint; a spacing element. In a preferable embodiment, the rigid support layer is affixed to the second surface of the decorative layer by an adhesive. More preferably during adhering a compressive pressure is applied to one or more of the decorative layer and the rigid support layer. Most preferably a curing heat is applied simultaneously to the compressive pressure, the curing heat being sufficient to cure the adhesive.

Preferably the laminate layer is affixed to the second surface of the rigid support layer by an affixing means selected from the range: an adhesive; a screw; a nail; a clamp; an interlocking joint; a spacing element. In a preferable embodiment, the rigid support layer is affixed to the second surface of the decorative layer by an adhesive. More preferably during adhering a compressive pressure is applied to one or more of the decorative layer and the rigid support layer. Most preferably a curing heat is applied simultaneously to the compressive pressure, the curing heat being sufficient to cure the adhesive.

In embodiments comprising a laminate layer, the decorative layer is adhered to the rigid support layer simultaneously to the rigid support layer being affixed to the laminate layer. Preferably said adhering occurs under a curing heat and compressive pressure.

Preferably the decorative layer comprises a decorative layer material selected from the group: wood; metal; mineral (e.g. gypsum); plasterboard; polymeric material; composite material; Perspex (trade mark); plastic; plywood; Oriented Strand Board (OSB); foamed PVC; aluminium based boards. It will be appreciated that any material suitable for use as a machined decorative layer may be used.

Preferably the rigid support layer comprises a rigid support layer material selected from the group: wood; metal; mineral (e.g. gypsum); plasterboard; polymeric material; composite material; Perspex (trade mark); plastic; plywood; OSB; foamed PVC; aluminium based boards. It will be appreciated that any material suitable for use as a rigid support layer may be used.

Preferably the laminate layer comprises a laminate layer material selected from the group: wood; metal; mineral (e.g. gypsum); plasterboard; polymeric material; plastic; vinyl; composite material; Perspex (trade mark); plastic; plywood; OSB; foamed PVC; aluminium based boards. It will be appreciated that any material suitable for use as a laminating layer may be used.

Preferably the decorative layer material and the rigid support layer material are different. In some embodiments, the decorative layer material and the rigid support layer material may be the same. The first decorative surface of the decorative layer can feasibly have a decorative finish applied thereto, post-machining. The decorative finish may comprise one selected from the range: a curable material such as, for example, paint, lacquer, varnish or a liquid-applied polymer; plaster; render; foil; PVC foil; a textured material such as, for example, flocking; fabric; textile. Any suitable finishing material will be appreciated, and may, for example be UV-, heat-and/or pressure-curable. The finish may be applied to the first decorative surface of the decorative layer using a suitable adhesive. It will be understood that the decorative layer material and any finish material applied to the decorative layer post-machining are distinct.

Preferably the decorative layer comprises a decorative layer thickness selected from the range: 3 mm to 50 mm. Most preferably the decorative layer thickness is selected from the range: 3 mm to 25 mm. In the context of the present invention, the decorative layer thickness will be understood by the skilled addressee to refer to the thickest portion of the decorative layer when taking the shortest distance between a point on the first decorative layer surface and a corresponding opposing point on the second decorative layer surface. The decorative layer thickness is preferably the thickness of the decorative layer post machining of the first decorative layer surface, and preferably prior to application of any decorative finish material.

Preferably the rigid support layer comprises a rigid support layer thickness selected from the range: 6 mm to 50 mm. Most preferably the rigid support layer thickness is selected from the range: 6 mm to 25 mm.

Preferably the laminate layer comprises a laminate layer thickness selected from the range: 0.2 mm to 10 mm. Most preferably the laminate layer thickness is selected from the range: 0.5 mm to 2 mm.

Preferably the decorative layer thickness and the rigid support layer thickness are sized relative to one another according to a thickness ratio of decorative layer thickness rigid support layer thickness, the thickness ratio selected from the range: 1: 0.2 to 1: 10.

In accordance with a second aspect of the present invention, there is provided a method of manufacturing a decorative panel having a machined decoration on a first surface thereof, the method comprising the steps of: i. providing a decorative layer having a first surface to be machined, and a second surface opposing the first surface; and then ii. affixing a rigid support layer to the second surface of the decorative layer.

Preferably the rigid support layer is affixed to the second surface of the decorative layer by a cured adhesive under compressive pressure. As such step ii. Preferably comprises a series of sub steps comprising: ii.a. applying a curable adhesive to one or both of the second surface of the decorative layer and the first support surface of the support layer; ii.b. positioning the first support surface of the support layer adjacent to the second surface of the decorative layer; and ii.c. simultaneously urging the decorative layer toward the support layer and applying a curing heat and/or a curing pressure sufficient to cure the curable adhesive.

Preferably the method further comprises the step of: iii. machining a decoration into the first surface of the decorative layer.

Step iii. can feasibly occur before or at any time after step ii. Step iii can be performed any time before step ii and the likelihood that this is the case is increased when the decoration to be machined into the decorative layer is minimal i.e. the machined depth is low relative to the thickness of the decorative layer, or if the decoration is applied sparsely upon the decorative layer.

Preferably the method further comprises the step of: iv. affixing a laminate layer to a second surface of the rigid support layer.

Step iv. may be performed prior to, or after step ii.

Preferably the decorative panel is a warp resistant decorative covering according to the first aspect of the present invention.

Detailed Description

Specific embodiments will now be described by way of example only, and with reference to the accompanying drawings, in which: FIG. 1 shows a sectional view of an example embodiment of a wall cover according to the first aspect of the present invention; FIG. 2 shows a perspective view of the example embodiment shown in FIG. 1; FIG. 3 shows a sectional view of a second example embodiment of a wall cover according to the first aspect of the present invention; FIG. 4 shows a perspective view of the example embodiment shown in FIG. 3; and FIG. 5 shows a flowchart representing the steps of an example embodiment of a method according to the second aspect of the present invention.

Referring to FIG. 1, an example embodiment 10 is shown of a warp resistant wall cover 10 according to the first aspect of the present invention. In the example 10 shown, the wall cover 10 comprises a monolithic, substantially planar MDF decorative layer 12 having a first decorative surface 14 and an opposing second surface 16. The decorative surface 14 comprises a decoration 15, machined into the decorative surface 14. The decoration 15 in the embodiment 10 shown takes the form of a series of grooves 15 etched into the timber of the decorative layer 12 to form a decorative pattern 15, seen more readily in the perspective view of the wall cover 10 shown in FIG. 2. The wall cover 10 further comprises a monolithic, substantially planar MDF support layer 18 having a first support surface 20 and a second surface opposing the first support surface 22. The first support surface 20 of the MDF support layer 18 is adhered to the second surface 16 of the decorative layer 12 by a urea resin adhesive layer 24. The adhesive layer 24 in the embodiment 10 shown is uniformly applied across the entire second surface 16 of the decorative layer 12 and the first support surface 20 of the support layer 18. As such, in use the support surface 20 of the support layer 18 may provide structural support to the second surface 16 of the decorative layer 12 across its surface area, thus causing the decorative layer 12 to resist the warping effect of the machined decoration 15.

In the example embodiment 10 shown, the decorative layer 12 comprises a decorative layer thickness 26 defining the shortest distance across the decorative layer 12 between one point on the first decorative surface 14 and a second opposing point on the second surface 16, taken at the thickest portion of the decorative layer 12.

Additionally, the support layer 18 comprises a support layer thickness 28 defining the shortest distance across the support layer 18 between one point on the first support surface 20 and a second opposing point on the second surface 22, taken at the thickest portion of the support layer 18.

In the embodiment shown 10, the decorative layer thickness 26 is 15 mm and the support layer thickness 28 is 25 mm. The material of the decorative layer 12 is the same as that for the support layer 18 and as such, the increased thickness of the support layer 18 imparts a greater warp-resistance upon the decorative layer 12 than if the decorative layer 12 were unsupported by the support layer 18. In another example, the support layer thickness (9 mm) less than the decorative layer thickness (15 mm), and the mere contact of the unmachined support layer with the machined decorative layer is sufficient to impart a warp resistance upon the decorative layer. In such embodiments the support layer material and decorative layer material may be the same. In other embodiments, the thinner support layer may comprise a support layer material of greater hardness, strength, flexural strength, and/or stiffness than the thicker decorative layer, and therefore apply a greater level of support against warping.

FIG. 3 shows an alternate example of a warp resistant wall cover 30 in accordance with the first aspect of the present invention. The wall cover 30 comprises a substantially planar plasterboard decorative layer 32 having a first decorative surface 34 and a second surface 36 opposing the first decorative surface 34. The first decorative surface 34 comprises a surface decoration 35 comprising a pattern machined into the first decorative surface 34. The decoration 35 can be more readily viewed in the perspective view of the second example embodiment 30 shown in FIG. 4. The wall cover 30 further comprises a substantially planar MDF support layer 38 having a first support surface 40 and an opposing second surface 42. The first support surface 20 of the MDF support layer 18 is adhered to the second surface 16 of the decorative layer 12 by a urea resin adhesive layer 44. The urea resin layer 44 is liquid applied mixed with a powder hardener. Other suitable adhesives will be appreciated. The adhesive layer 44 in the embodiment 10 shown is uniformly applied across the entire second surface 36 of the decorative layer 32 and the first support surface of the support layer 38. The wall cover 30 further comprises a planar laminate layer 50 having a first laminate surface 52 and a second laminate surface 54 opposing the first laminate surface 52. The first laminate surface 52 of the laminate layer 50 is adhered to the second surface 42 of the support layer 38 by a urea resin adhesive layer 56 which is equivalent to that 44 previously described. As such, in use the support layer 38 and the laminate layer 50 provide a cumulative supporting effect, providing structural support to the decorative layer 32 across its surface area, thus causing the decorative layer 32 to resist the warping effect of the machined decoration 35.

In the example embodiment 30 shown, the decorative layer 32 comprises a decorative layer thickness 46 defining the shortest distance across the decorative layer 32 between one point on the first decorative surface 34 and a second opposing point on the second surface 36, taken at the thickest portion of the decorative layer 32.

Additionally, the support layer 38 comprises a support layer thickness 48 defining the shortest distance across the support layer 38 between one point on the first support surface 40 and a second opposing point on the second surface 42, taken at the thickest portion of the support layer 38.

In the embodiment shown 30, the decorative layer thickness 46 is 65 mm and the support layer thickness 28 is 97.5 mm. The material of the decorative layer 32 comprises a lower hardness, strength, flexural strength and/or stiffness characteristic than that of the support layer 38 and as such, the increased hardness, strength, flexural strength and/or stiffness of the support layer 38 imparts a greater warp-resistance upon the decorative layer 32 than if the decorative layer 32 were unsupported by the support layer 38.

Referring to FIG. 5, an example embodiment 60 of a method of manufacturing a warp resistant covering according to the second aspect of the present invention is shown, the method 60 comprising the steps of: i. providing a decorative layer having a first surface to be machined, and a second surface opposing the first surface 62; ii. providing a rigid support layer affixed to the second surface of the decorative layer, wherein the rigid support layer may be affixed to a wall 64; and then iii. machining a decoration into the first surface of the decorative layer 66.

The embodiment 60 shown comprises the step of machining a decoration into the first surface of the decorative layer 66, which occurs following the step of providing a rigid support layer affixed to the second surface of the decorative layer, wherein the rigid support layer may be affixed to a wall 64. Embodiments will be appreciated wherein the decorative layer is machined prior to affixing the rigid support layer to the decorative layer. The method may also comprise the step of applying or affixing the covering to a wall.

It will be appreciated that the above described embodiments are given by way of example only and that various modifications may be made to the described embodiments without departing from the scope of the invention as defined in the appended claims. For example, MDF is used the support panel and, in one example, the decorative layer. Suitable forms of MDF include, but are not limited to, standard/premium grade; moisture resistant; FR Class C; FR Class B; deep rout; and Through Coloured MDF (e.g. black). It will be appreciated that any suitable material as herein described may be used. The embodiments described involve a wall covering. Embodiments will be appreciated wherein the covering is suitable for a wall, a door, or any suitable form of furniture.

Claims

CLAIMS1. A warp resistant decorative covering, the covering comprising: a decorative layer having a first surface to be machined, and a second surface opposing the first surface; and a rigid support layer affixed to the second surface of the decorative layer at a first support surface of the rigid support layer.
2. A warp resistant decorative covering as claimed in claim 1, wherein the rigid support layer is arranged to be affixed to one of, a wall, a door, an item of furniture.
3. A warp resistant decorative covering as claimed in claim 1 or claim 2, wherein the rigid support layer abuts the second surface of the decorative layer.
4. A warp resistant decorative covering as claimed in claim 3, wherein the second surface of the decorative layer is arranged to abut the rigid support layer across a maximum area of the second surface.
5. A warp resistant decorative covering as claimed in claim 4, wherein the second surface is arranged to abut the rigid support layer across an entirety of the second surface.
6. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the rigid support layer is affixed to the second surface of the decorative layer by an affixing means selected from the range: an adhesive; a screw; a nail; a clamp; an interlocking joint; a spacing element.
7. A warp resistant decorative covering as claimed in claim 6, wherein the affixing means is a heat-and/or pressure-curable adhesive.
8. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the warp resistant covering further comprises a laminate layer affixed to a second surface of the rigid support layer, the second surface of the rigid support layer opposing the first support surface.
9. A warp resistant decorative covering as claimed in claim 8, wherein the laminate layer is affixed to the second surface of the rigid support layer by an affixing means selected from the range: an adhesive; a screw; a nail; a clamp; an interlocking joint; a spacing element.
10. A warp resistant decorative covering as claimed in claim 9, wherein the affixing means is a heat-and/or pressure-curable adhesive.
11. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the decorative layer comprises a decorative layer material selected from the group: wood; metal; mineral (e.g. gypsum); plasterboard; polymeric material; composite material; Perspex (trade mark); plastic; plywood; Oriented Strand Board (OSB); foamed PVC; aluminium based boards.
12. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the rigid support layer comprises a rigid support layer material selected from the group: wood; metal; mineral (e.g. gypsum); plasterboard; polymeric material; composite material; Perspex (trade mark); plastic; plywood; OSB; foamed PVC; Aluminium based boards.
13. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the laminate layer comprises a laminate layer material selected from the group: wood; metal; mineral (e.g. gypsum); plasterboard; polymeric material; plastic; vinyl; composite material; Perspex (trade mark); plastic; plywood; OSB; foamed PVC; aluminium based boards.
14. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the support layer material comprises a greater hardness, strength, flexural strength and/or stiffness than the decorative layer material.
15. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the decorative layer comprises a decorative layer thickness selected from the range: 3 mm to 50 mm.
16. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the rigid support layer comprises a rigid support layer thickness selected from the range: 6 mm to 50 mm.
17. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the laminate layer comprises a laminate layer thickness selected from the range: 0.2 mm to 10 mm.
18. A warp resistant decorative covering as claimed in any one of the preceding claims, wherein the decorative layer thickness and the rigid support layer thickness are sized relative to one another according to a thickness ratio of decorative layer thickness: rigid support layer thickness, the thickness ratio selected from the range: 1: 0.2 to 1: 10.
19. A method of manufacturing a decorative panel having a machined decoration on a first surface thereof, the method comprising the steps of: i. providing a decorative layer having a first surface to be machined, and a second surface opposing the first surface; and then ii. affixing a rigid support layer to the second surface of the decorative layer.
20. A method of manufacturing as claimed in claim 19, wherein step fi. comprises a series of sub steps comprising: ii.a. applying a curable adhesive to one or both of the second surface of the decorative layer and the first support surface of the support layer; ii.b. positioning the first support surface of the support layer adjacent to the second surface of the decorative layer; and ii.c. simultaneously urging the decorative layer toward the support layer and applying a curing heat and/or a curing pressure sufficient to cure the curable adhesive.
21. A method of manufacturing as claimed in claim 19 or 20, wherein the method further comprises the step of: iii. machining a decoration into the first surface of the decorative layer.
22. A method of manufacturing as claimed in claim 19, claim 20 or claim 21, wherein the decorative panel is a warp resistant decorative covering as claimed in any one of claims 1 to 18.