Decorative architectural element and method for making

• US 20110225917A1
• Filed: 03/16/2010
• Published: 09/22/2011
• Est. Priority Date: 03/16/2010
• Status: Abandoned Application

• Current Assignee: Fantasy Factory, LLC
• Original Assignee: Fantasy Factory, LLC
• Inventors: Golden, Jennifer, Sexton, Stephen J.
• Application Number:
  US12/661,360
• Publication Number:
  US 20110225917A1
• Time in Patent Office: Days
• US Class Current: 52/316
• CPC Class Codes: B29C 2795/002 before shaping
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29K 2023/083 EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29L 2031/724 Doors
• CPC Class Codes: E06B 3/7001 Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces

Abstract

A method for making a decorative architectural element is disclosed, which includes the steps of designing a vacuum form mold forming a three dimensional decorative shape for the architectural element, cut a moldable plastic sheet in a size and shape to fit over the vacuum form mold, designing a color graphic, print the color graphic onto a vinyl wrap which corresponds in size and shape to fit over the vacuum form mold covered with the plastic sheet, vacuum forming the plastic sheet over the vacuum form mold and the vinyl wrap over the plastic sheet. The plastic sheet takes the shape of the vacuum form mold and the vinyl wrap adheres to the molded plastic sheet. The molded plastic sheet and the attached molded vinyl wrap are then removed from the vacuum mold. One arrangement includes the step of affixing the molded plastic sheet with the attached molded vinyl wrap to the architectural element. The molded vinyl wrap faces away from the architectural element, so that the color graphic printed on the vinyl wrap is visible. A decorative architectural element includes a basic architectural element, a molded plastic sheet fitting over the basic architectural element giving the architectural element a decorative shape, and a molded vinyl wrap molded over the molded plastic and facing away from the basic architectural element. The molded vinyl wrap is printed with a color graphic.

Claims

1. A method for making a decorative architectural element, comprising in combination the steps of:

designing a vacuum form mold forming a three dimensional decorative shape for the architectural element;

cut a moldable plastic sheet in a size and shape to fit over the vacuum form mold;

designing a color graphic;

print the color graphic onto a vinyl wrap which corresponds in size and shape to fit over the vacuum form mold covered with the plastic sheet;

vacuum forming the plastic sheet over the vacuum form mold and the vinyl wrap over the plastic sheet, whereby the plastic sheet takes shape of the vacuum form mold and whereby the vinyl wrap adheres to the molded plastic sheet; and

removing the molded plastic sheet and the attached molded vinyl wrap from the vacuum mold.

2. A method according to claim 1, further comprising the step of affixing the molded plastic sheet with the attached molded vinyl wrap to the architectural element, wherein the molded vinyl wrap faces away from the architectural element, whereby the color graphic printed on the vinyl wrap is visible.

3. A method according to claim 1, wherein the decorative architectural element is a decorative door frame.

4. A method according to claim 3, further comprising the step of removing the portions of the molded plastic sheet and the molded vinyl wrap which would cover the door.

5. A method according to claim 4, further comprising the step of affixing the molded plastic sheet with the attached molded vinyl wrap to a door frame, wherein the molded vinyl wrap faces away from the door frame, whereby the color graphic printed on the vinyl wrap is visible.

6. A method according to claim 1, wherein the decorative architectural element is a decorative door.

7. A method according to claim 6, further comprising the step of affixing the molded plastic sheet with the attached molded vinyl wrap to a door, wherein the molded vinyl wrap faces away from the door frame, whereby the color graphic printed on the vinyl wrap is visible.

8. A decorative architectural element comprising in combination:

a basic architectural element;

a molded plastic sheet fitting over the basic architectural element giving the architectural element a decorative shape; and

a molded vinyl wrap molded over the molded plastic and facing away from the basic architectural element, wherein the molded vinyl wrap is printed with a color graphic.

9. A decorative architectural element according to claim 8 wherein the architectural element is a door.

10. A decorative architectural element according to claim 8 wherein the architectural element is a door frame.