WO2006019754A1

WO2006019754A1 - Synthetic panel and method of making the same

Info

Publication number: WO2006019754A1
Application number: PCT/US2005/024744
Authority: WO
Inventors: Scott W. Freeman; Thomas G. Bailey; Tom Heiman
Original assignee: Intier Automotive Inc.
Priority date: 2004-07-16
Filing date: 2005-07-12
Publication date: 2006-02-23

Abstract

A method for manufacturing a synthetic panel (10, 10', 10', 10'') comprising the steps of introducing a synthetic material (12) into a mold tool, introducing a reinforcing material (14) into the synthetic material and allowing the synthetic and reinforcing material (14) to form a synthetic panel (10') having a unitary construction. In one embodiment, the reinforcing material (14) is not introduced into the synthetic material (12). In another embodiment, the synthetic panel (10') includes a scrim material (16) encapsulated by the synthetic material (12). In yet another embodiment, the synthetic panel (10'') includes a cover material (20) on one of the exposed surfaces (18, 19) with an optional foam material (21) between the cover material (20) and the synthetic material (12). The synthetic panel (10) may undergo a three-phase post-treatment operation. The synthetic panel (10, 10', 10', 10'') may be used as a floor tile, a ceiling tile, or the like.

Description

SYNTHETIC PANEL AND METHOD OF MAKING SAME

Technical Field

The present invention generally relates to a tile or panel. More particularly, the invention relates to a method for manufacturing a tile or panel, such as a ceiling panel or a floor tile, made of a synthetic material, for example, a mixture of isocynate and polyol components.

Background of the Invention

Tiles have been commonly used in homes and office buildings. In one application, for example, tiles that are applied to a floor or wall typically comprise a ceramic material. Ceramic tiles, however, are undesirably heavy, extremely brittle, have sharp edges, and require specific tools for cutting and installation. In some circumstances, additional materials, such as a cement board underlayment, may be required prior to adhering on a floor or wall with an adhesive.

Upon adhering the ceramic tile to a floor or wall, finishing steps requiring additional materials, such as grouting and sealants, are also required. Additionally, because the adhesive, grouting, and sealants associated with ceramics tile installation typically require long curing periods, completion of the installation procedure may require as much as three days of time and multiple visits to the work site by a skilled tradesman. Once installed, ceramic tiles are typically cold to the touch and have poor acoustic properties.

In another application, for example, tiles are applied to a metal or plastic grid located adjacent a ceiling, which is commonly referred to in the art as a drop ceiling. Drop ceiling tiles are typically made from a pressed fibrous material of wood or paper, which are prone to being easily damaged during shipping or installation. If exposed to moisture, drop ceiling tiles may become moldy, and in some circumstances, may undesirably sag or bow within the grid over time.

Although adequate for most applications, the tiles described above include many inherent deficiencies including, for example, manufacturing deficiencies, installation deficiencies, and maintenance deficiencies. As such, a need exists for an improved tile that reduces and eliminates conventional tile deficiencies.

Brief Description of the Drawings

The inventors of the present invention have recognized these and other problems associated with conventional tiles. The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a synthetic tile or panel according to one embodiment of the invention;

Figure 2 is a cross-sectional view of the synthetic panel taken along line 2-2 of Figure i;

Figure 3 is a cross-sectional view of a synthetic panel with reinforcing fibers according to another embodiment of the invention taken along line 2-2 of Figure 1;

Figure 4 is a cross-sectional view of a synthetic panel with reinforcing scrim material according to another embodiment of the invention taken from line 2-2 of Figure 1;

Figure 5 is a cross-sectional view of a synthetic panel with a cover material according to another embodiment of the invention taken from line 2-2 of Figure 1;

Figure 6 is a perspective view of a synthetic panel comprising a plurality of tile segments according to another embodiment of the invention;

Figure 7 is a cross-sectional view of the synthetic panel taken from line 6-6 of Figure

6;

Figure 8 is a flow chart diagram illustrating a method of manufacturing a synthetic tile according to an embodiment of the invention; and

Figure 9 is a flow chart diagram illustrating a method of post-treatment of the synthetic tile according to an embodiment of the invention.

Detailed Description of the Invention

The above described disadvantages are overcome and a number of advantages are realized by an inventive synthetic tile or panel, which is seen generally at 10 in Figures 1 and 2. The synthetic panel or tile 10 comprises a generally rigid, synthetic material 12 having a unitary construction. According to one embodiment of the invention, the synthetic material 12 preferably comprises, for example, a mixture of isocynate and polyol. However, it will be appreciated that a single, unmixed composition of synthetic material or other mixtures of synthetic materials are within the scope of the invention. If the synthetic material comprises a mixture of isocynate and polyol, the ratio of isocynate to polyol may be approximately equal to 1.62: 1. However, it will be appreciated that other mixture ratios of isocynate and polyol are within the scope of the invention. For example, the ratio of isocynate to polyol may be approximately equal to 1.78:1.

As illustrated in Figure 2, the synthetic panel 10 includes vertical and horizontal faux grout lines 24 and vertical and horizontal connecting flanges 26 integrally formed with the synthetic material 12. As such, the synthetic panel 10 may also include flange recesses 28 that receive connecting flanges 26 when multiple synthetic tiles 10 are placed adjacent one another. If desired, the synthetic panel 10 may not include connecting flanges 26 and flange recesses 28. The synthetic material 12 forming the panel 10 has a relatively high density that is particularly suitable for use as a floor tile, or the like.

Referring now to Figure 3, another embodiment of the invention comprises a synthetic panel 10' that includes a reinforcing material 14 encapsulated within the synthetic material 12 by using a reinforced reaction injection molding (RRIM) process. According to one aspect of the invention, the reinforcing material 14 may include reinforcing fibers, such as glass fibers, carbon fibers, or the like. The reinforcing fibers 14 may alternatively include natural fibers, such as, for example, hemp fibers, coconut fibers, kanuf fibers, flax fibers, or the like. By encapsulating the reinforcing material 14 within the synthetic material 12, the synthetic material 12 can have a relatively lower density as compared to the synthetic material 12 for forming the panel 10 without the reinforcement material 14. Thus, the synthetic panel 12' can be suitable for applications that require the use of a lighter-weight panel or tile, for example, a ceiling tile, wall panel, or the like.

According to an alternative embodiment shown in Figure 4, a synthetic tile or panel 10" does not include the reinforcing fibers 14 as in the synthetic panel 10', but rather the synthetic panel 10" includes a layer of reinforcing scrim material 16 bonded to a bottom or rear surface 18, a top or front surface 19, or both. Alternatively, the scrim material 16 may be encapsulated within the synthetic material 12. Similar to the synthetic panel 10', by providing the scrim material 16 on one or both exterior surfaces, 18, 19 of the synthetic material 12, the synthetic material 12 can have a relatively lower density as compared to the synthetic material 12 for forming the panel 10 without the scrim material 16. Thus, the synthetic panel 12' can be most suitable for applications that require the use of a lighter weight tile, such as a ceiling tile or the like.

In an alternative embodiment shown in Figure 5, a synthetic tile or panel 10"' includes a cover material 20 bonded to one of the top or bottom surfaces 18, 19, for example, the top surface 19 of the synthetic material 12. The cover material 20 may comprise any desirable material, such as, for example, vinyl, acrylic, thermoplastic olefin (TPO), polyethylene terepthalate (PET), cross-linked polyolefin (XLPO), or the like. Alternatively, the cover material 20 may comprise a decorative cloth material, or the like. If desired, the cover material 20 maybe bonded to the top surface 19 of the synthetic panel 10'" by disposing a layer of foam material 21 between the cover material 20 and the synthetic material 12 by using a foam-in-place operation, or the like. In addition, the cover material 20 may have an embossed appearance for displaying, for example, a manufacturer's logo, or the like. As illustrated, the synthetic panel 10'" does not include the reinforcing fibers 14 and/or the scrim material 16. However, if desired, the reinforcing scrim 16 maybe included.

It will be appreciated that the invention can be practiced with any desirable combination of the panels 10, 10', 10", 10"' mentioned above. For example, the synthetic panel may comprise a synthetic material without reinforcing fibers 14 or scrim material 16 and include the cover material 20 with or without the foam material 21. Other combinations of the synthetic panel are within the scope of the invention.

For example, in another embodiment shown in Figures 6 and 7, a single, large panel 100 made of the synthetic material to give the appearance of a plurality of integrally-formed synthetic tile elements 34 constructed similarly to the synthetic panels 10, 10', 10", 10'". Each tile element may be separated by vertical and horizontal faux grout lines 30, similar to the vertical and horizontal faux grout lines 24 in the earlier embodiments. The panel 100 may include connecting flanges 26, similar to the connecting flanges 24 in the earlier embodiments.

Referring to Figure 8, a method for manufacturing the panel 10 by using a RIM process is described. At step S8.1, the mold tool (not shown) is opened. Optionally, at step S8.2, a release agent may be applied by adding the in-mold release (IMR) agent to the mixture and/or by applying the external mold release (EMR) agent to one or both mold surfaces of the mold tool to assist in releasing the panel 10 from the mold tool upon completion of the mold cycle. Then, if desired, at step S8.3, an optional in-mold coating (IMC) is applied to a surface of the mold tool to provide a decorative surface finish to the panel 10. The decorative surface finish may include any desirable aesthetic appearance with multiple colors or designs, such as streaking, splattering, pad printing, clouding, stone, marble, or the like. If it is determined that the IMC application at step S8.3 is not desired, the desirable aesthetic appearance may be post- applied to the panel 10 upon completion of the mold cycle, if desired.

At step S8.4, the synthetic material 12 is prepared prior to injection into the mold tool at step S8.6. For example, the isocynate and polyol may be separately maintained in a holding tank at a temperature approximately equal to 80⁰F, and then mixed together at the mixing head or injection nozzle. However, the temperature may vary depending on environmental operating conditions, such as the tool temperature, or the like. For example, the temperature of the holding tank may be approximately equal to 90⁰F when the tool temperature is approximately equal to 150⁰F. In another example, the temperature of the holding tank may be approximately equal to 60⁰F when the tool temperature is approximately equal to 175⁰F.

At step S8.5, the synthetic material is injected in the mold tool. A metered amount of synthetic material may be injected to yield a specific material density of the panel 10. For example, if a higher density of the panel 10 is desired, a relatively larger amount of synthetic material 12 is metered to substantially fill 100% of the volume of the mold tool. According to an embodiment, the synthetic material 12 is injected for 1.9 seconds at a metering rate approximately equal to 300 gram per second (a total of 570 grams of synthetic material 12) to yield a high density panel 10 having approximately 450 grams of synthetic material 12 per square foot of the synthetic panel 10. As such, when foaming and expansion of the synthetic material occurs, a relatively high density panel 10 may be yielded due to the compression of the synthetic material under tonnage of the closed mold tool. Preferably, a specific gravity of a high-density synthetic material is approximately equal to the range of about 0.60 to about 1.00, and preferably in the range of about 0.65 to 0.70. It will be appreciated that the invention is not limited by the metered amounts of synthetic material that is injected into the mold tool. For example, the synthetic material 12 can be injected for 1.1 seconds at a metering rate approximately equal to 400 gram per second (a total of 440 grams of synthetic material).

Conversely, the synthetic material 12 may be metered to yield a lower density panel 10 by injecting a relatively smaller amount of synthetic material that is less than 100% of the volume of the mold tool such that the synthetic material, upon injection, is permitted to expand into free space when the mold tool is closed. According to one embodiment of the invention, the synthetic material 12 is injected for approximately 1.0 seconds at a metering rate approximately equal to 300 grams per second to yield a low density panel 10 having approximately 110 grams of synthetic material 12 per square foot of the synthetic panel 10. In an alternative embodiment, a lesser amount of synthetic material 12 may be metered at step S 8.5 if a liquid, such as water, and the like, is introduced to the polyol component of the mixture. Upon introducing water to the polyol component, the cellular structure foams at a greater rate, which causes an even lower density of the panel 12. According to one aspect of the invention, a specific gravity of a low-density synthetic material is approximately equal to the range of 0.10 to 0.60.

Upon metering and injecting the synthetic material 12, the mold tool surface is preferably heated to a temperature in the range approximately equal to 130-190⁰F, for example about 150⁰F. It will be appreciated that the mold tool surface temperature range may include different temperatures depending on the material of the mold tool surface. For example, if the mold tool surface is made of aluminum and is heated to approximately 140⁰F, the cure time may be approximately ninety seconds. At steps S8.6 and S8.7, the mold tool is closed, and the synthetic material is cured to form the panel 12 made of synthetic material of unitary construction. Then, at step S8.9, the mold tool is opened and the panel 12 is removed from the mold tool.

A method for manufacturing the panel 10' by using a RRIM process is similar to the method for manufacturing the panel 10, except that the reinforcing fibers 14 are introduced into the synthetic material at the mixing head while injecting the synthetic material 12 into the mold tool at step S8.5. Instead of forming the panel 10' using the RRIM process, a method for manufacturing the panel 10" by using a SRIM process is similar to the method for manufacturing the panel 10, except that the scrim material 16 is placed on one of the mold halves of the mold tool prior to injecting the synthetic material 12 into the mold tool at step S 8.5. The scrim material 16 is preferably allowed to be encapsulated by the synthetic material 12.

A method for manufacturing the panel 10'" having the cover material 20 can be formed by using the RIM, RRIM or SRIM process described above, except that the decorative cover 20 is introduced onto the surface of the mold tool instead of the IMC at step S8.3, thereby providing a decorative surface finish to the panel 10'".

Referring now to Figure 9, the panel 10, 10', 10", 10'" may undergo additional, optional treatment operations once removed from the mold tool. For example, the panel 10, 10', 10", 10'" may undergo a three-phase post-operation when the panel is used as a floor tile. The first phase of the post-treatment operation may include a first scuff cleaning step at S9.1 to prepare the top surface of the panel, a roll coating step at S9.2 to apply a first layer of wear resistant material, such as a clear coat material, to the top surface of the panel, and a first curing step at S9.3 to partially cure the wear resistant material. In step 9.2, the roll coating step is considered a "tie coat" that links the first layer of the clear coat to the synthetic panel. In step S9.3, the wear resistant material is preferably partially cured to a gel state by using low intensity ultra-violet (UV) rays. In one embodiment, the wear resistant material may comprise a urethane material, a polyurethane material, or the like, for improving weathering and resistance to ultra-violet (UV) rays of the panel.

The second phase post-treatment operation may include a second roll coating step at S9.4 to apply a second layer of the wear resistant material, and a second curing step at S9.5 to partially cure the wear resistant material. In step S9.5, the wear resistant material is preferably partially cured to a gel state, but may be almost in a fully cured state by using at least one-half the intensity of UV rays. An optional stain or paint may be also applied during the second roll coating step S9.4 to provide a desired color to the top surface of the panel 10, 10', 10", 10'". In step 9.4, the roll coating step is considered a "flex coat" that is formulated to follow any impact against the synthetic panel without cracking or chipping. The third and final phase of the post-treatment operation may include a second scuff cleaning step at S9.6, a third roll coating step at S9.7 to apply a third layer of wear resistant material, and a third curing step at S9.7 to fully cure the wear resistant material. It is desirable that the post-treatment operation can be performed in a relatively short period of time, for example, 60-90 seconds. In step 9.7, the roll coating step is considered a "top coat" that carries the wear resistant characteristics that resist cracking and marring of the synthetic panel.

It will be appreciated that any or all of the three roll coating step mentioned above may also having additional components added to the wear resistant material, such as an anti¬ bacterial component, a slip resistance component, and the like.

It will also be appreciated that the wear resistant material may be applied in a one-step process (as a single layer of material), such as a spraying application or a single component roll coating process that would carry characteristics of all three previously mentioned roll coating steps in one components. However, these additional post-treatment steps may be omitted when making the final product. For example, if a low density synthetic material is prepared at step S8.4, the finishing procedure may only include an edge trimming operation by using, for example, a water jet, or the like, after being removed from the mold tool. Then, the trimmed panel may be packaged and shipped. In application, the panel 10, 10', 10", 10'" may be a ceiling tile applied to a drop ceiling grid (not shown) that is somewhat less rigidified and lighter in weight due to the low density composition of the synthetic material.

The present invention has been described with reference to certain exemplary embodiments thereof. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.

Claims

ClaimsWHAT IS CLAIMED IS:

1. A method for manufacturing a synthetic panel (10, 10', 10", 10'"), comprising the steps of: introducing a synthetic material (12) into a mold tool; introducing a reinforcing material (14) into the synthetic material (12); and curing the synthetic material (12) and the reinforcing material (14) to form a synthetic panel (10, 10', 10", 10'") of unitary construction in which the synthetic material (12) forms both a top surface (19) and a bottom surface (18) of the synthetic panel (10, 10', 10", 10'").

2. A method according to Claim 1, whereby the synthetic panel (10, 10', 10", 10'") comprises a floor tile, a ceiling tile, or a wall panel.

3. A method according to Claim 1, whereby the reinforcing material (14) comprises glass fibers encapsulated within the synthetic material (12).

4. A method according to Claim 1, whereby the reinforcing material comprises a scrim material (16) at least partially encapsulated within the synthetic material (12).

5. A method according to Claim 1, whereby the synthetic material (12) comprises a mixture of isocyanate and polyol.

6. A method according to Claim 5, whereby a ratio of isocyanate to polyol is about 1.62:1.

7. A method according to Claim 1, further comprising the step of performing a three-phase post-treatment operation of the synthetic panel (10, 10', 10", 10'").

8. A method according to Claim 1 , whereby the synthetic panel (10, 10', 10", 10"') comprises a plurality of integrally-formed tile elements (34).

9. A method according to Claim 1, further comprising the step of bonding a cover material (20) to one of the top and bottom surfaces (18, 19) of the synthetic panel (10, 10', 10", 10'").

10. A method according to Claim 9, further comprising the step of providing a foam material (21) between the cover material (20) and the synthetic panel (10, 10', 10", 10"') using a foam-in-place operation.

11. A method according to Claim 1 , wherein the synthetic material (12) has a specific gravity in a range between about 0.1 to 1.0.