Door panel
First Claim
1. A composite panel comprising, a series of layers bonded together having two faces and an edge periphery,one face comprising a layer of decorative material, adjacent said periphery said decorative material curing toward a second face to define a convex surface terminating at said periphery,said decorative material being bonded to one side of a first foamed resin layer by an adhesive at least partially impregnating said foam, said foam being open celledmeans adhered to said composite panel for connecting the panel to a substrate andthe periphery of said panel being compressed to a minimal thickness with the decorative material terminating substantially at said second face.
6 Assignments
0 Petitions
Accused Products
Abstract
A panel formed as a laminate with a decorative fabric at the exposed face includes a pair of foamed resin layers as backing material. Between the foamed resin layers is a fiber glass layer for strength. Means are provided to attach the panel to a substrate.
46 Citations
20 Claims
-
1. A composite panel comprising, a series of layers bonded together having two faces and an edge periphery,
one face comprising a layer of decorative material, adjacent said periphery said decorative material curing toward a second face to define a convex surface terminating at said periphery, said decorative material being bonded to one side of a first foamed resin layer by an adhesive at least partially impregnating said foam, said foam being open celled means adhered to said composite panel for connecting the panel to a substrate and the periphery of said panel being compressed to a minimal thickness with the decorative material terminating substantially at said second face.
-
7. A process for forming a panel comprising,
providing a mold having upper and lower sections, the upper section having a first planar surface facing the lower section, the lower section including a second planar section, providing a border ridge around the second planar section, said ridge projecting toward said upper mold section and including a sharp cutting edge at its upper most edge which extends around the second planar surface, the height of said ridge being less than abut one-half inch above the second planar section, providing a decorative layer to provide one face for said panel, cutting the decorative layer to about the shape defined by said sharp edge, placing the decorative layer on the lower mold in a position that the decorative layer covers the sharp edge and extends beyond said sharp edge at all locations, providing a first layer of open celled foamed resin of a thickness in the range of about 1/4-1/2 inches, impregnating the foamed layer with an adhesive in an amount which will fill the cells upon compression to the desired thickness of the cured panel, placing the first layer of foam over the decorative layer in a manner to completely cover the decorative layer, pressing the two mold sections together to compress the layers between the planar sections and at the sharp ridge edge, heating the lower mold section to about 150° - F. and the upper mold section to about 250°
F. for a period of time adequate to cure the adhesive. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
- F. and the upper mold section to about 250°
Specification