STRUCTURAL PANELS AND METHODS OF MAKING THEM

• US 20100132303A1
• Filed: 12/03/2008
• Published: 06/03/2010
• Est. Priority Date: 12/03/2008
• Status: Abandoned Application

• Current Assignee: Kevin Patrick Gill
• Original Assignee: Kevin Patrick Gill
• Inventors: Gill, Kevin Patrick
• Application Number:
  US12/327,075
• Publication Number:
  US 20100132303A1
• Time in Patent Office: Days
• US Class Current: 52/745.130
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: E04F 13/08 composed of a plurality of similar covering or lining elements, E04F13/072 takes precedence; borders, skirtings E04F19/02; of webs or fabrics E04F13/002; fixing strips E04F19/06; separate provisional spacers between adjacent tiles E04F21/0092; implements or means for setting tiles E04F21/18
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24868 Translucent outer layer

Abstract

A structural panel includes an impermeable solid base sheet that has one side adapted to adhere to a surface such as by mortar or grouting and having a second side adapted to receive decorative material. For example, the second side may include pieces forming a mosaic or may include artwork in relief or colors and the like. The panel is sealed with a smooth outer surface that may be transparent or translucent or may be partly transparent but colored. This material is the equivalent of self-leveling materials such as those that form a smooth level surface such as a liquid or semi-solid and then harden while maintaining the smooth surface.

Claims

1. A structural panel comprising:

a solid base sheet;

at least one decorative member fastened to the solid base sheet;

a seal having a smooth outer surface and formed of at least one light passing material, wherein the at least one decorative member may be viewed through the at least one light passing material.

2. A structural panel in accordance with claim 1 wherein the solid base sheet is an impermeable sheet.

3. A structural panel in accordance with claim 1 wherein the seal includes at least one functional sized and shaped seal.

4. A structural panel in accordance with claim 2 wherein the impermeable sheet is a solid sheet having an uneven surface.

5. A structural panel in accordance with claim 1 in which the solid base sheet includes wax

6. A structural panel in accordance with claim 4 wherein the impermeable sheet is a polyurethane sheet.

7. A structural panel in accordance with claim 1 wherein the at least one decorative member is a mosaic consisting of multiple decorative separate pieces each of which is fastened to the solid base sheet.

8. A structural panel in accordance with claim 1 wherein the at least one decorative member is a painting.

9. A structural panel in accordance with claim 1 wherein the at least one decorative member is a layer of material with a surface having a decorative shape.

10. A structural panel in accordance with claim 1 wherein the seal is a clear transformable material.

11. A structural panel in accordance with claim 10 wherein the clear transformable material is a hardenable time transformable material.

12. A structural panel in accordance with claim 10 wherein the clear transformable material is a hardenable chemically transformable material.

13. A structural panel in accordance with claim 12 wherein the hardenable chemically transformable material is an epoxy material.

14. A method of making a structural panel, comprising the steps of:

incorporating a solid base sheet;

applying at least one decorative member to the solid base sheet; and

applying a functional sized and shaped seal.

15. The method of claim 14 wherein the step of incorporating a solid base sheet includes the step of incorporating an impermeable sheet.

16. The method of claim 14 wherein the step of incorporating a solid base sheet includes the step of incorporating a semi-permeable sheet.

17. The method of claim 14 wherein the step of incorporating a solid base sheet includes the steps of:

obtaining a permeable base sheet;

closing openings of the permeable base sheet with a removable material prior to applying the at least one decorative member; and

applying an adhesive material while the openings of the permeable base sheet are closed.

18. The method of claim 14 wherein the step of applying at least one decorative member includes the step of:

applying an adhesive to the solid base sheet; and

applying the at least one decorative member.

19. The method of claim 14 wherein the step of applying a functional sized and shaped seal comprises the steps of applying a self-leveling coat to the solid base sheet and said at least one decorative member, wherein the self-leveling coat forms a smooth protective layer.

20. The method of claim 19 wherein the step of applying a self-leveling coat comprises the step of applying a light passing epoxy wherein the at least one decorative member may be seen through the epoxy.

21. The method of claim 20 wherein the self-leveling coat is transparent.

22. The method of claim 20 wherein the self-leveling coat is colored.

23. A method of installing structural panels, comprising the steps of:

forming a plurality of structural panels each of which comprises a solid base sheet, at least one decorative member fastened to the solid base sheet and a seal having a smooth outer surface and formed of at least one light passing material, wherein the at least one decorative member may be viewed through the at least one light passing material; and

delivering the plurality of structural panels to a purchaser wherein the structural panels may be installed on a surface.

24. A method in accordance with claim 23 further including the steps of laying down mortar on a surface to receive the structural panels and pressing the solid base sheet against it.

25. A method in accordance with claim 23 further including the step of fastening the panels to a vertical surface with brackets.

26. A method in accordance with claim 23 further including the step of fastening the panels to a horizontal surface with brackets.