Architectural laminate panel with embedded compressible objects and methods for making the same
DCFirst Claim
1. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
- softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step;
wherein the first pressure is between about 5 psi and about 10 psi, and the first temperature comprises a temperature of up to 300°
F.;
further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and
pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure.
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Abstract
A decorative laminate panel comprises compressible objects embedded inside, wherein the compressible objects would be flattened in unnatural shapes under conventional processes. For example, an exemplary decorative laminate product comprises thatch reed, willow reed, bamboo, weeds, grasses, twigs and branches of a tree or bush, beans, and so forth. In at least one exemplary implementation of the present invention, an extruded sheet, such as PETG or polycarbonate, is softened and melted around the compressible materials such that the compressible materials do not deform. Imperfections in the decorative laminate panel can be easily removed, thereby allowing for producing a high quality decorative laminate panel with high efficiency and relatively low cost compared with conventional methods and materials.
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Citations
35 Claims
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1. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step; wherein the first pressure is between about 5 psi and about 10 psi, and the first temperature comprises a temperature of up to 300°
F.;further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step, wherein the first pressure is between about 5 psi and about 10 psi; further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure; wherein the second pressure and temperature comprise a pressure of up to 40 psi and a temperature of up to 350°
F. - View Dependent Claims (19, 20)
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21. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step, wherein the first pressure is between about 5 psi and about 10 psi; further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure and the third temperature is greater than the second temperature; wherein the third pressure and temperature comprise a pressure of up to 92 psi and a temperature of up to 360°
F. - View Dependent Claims (22, 23)
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24. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step; wherein the first pressure is between about 5 psi and about 10 psi, and the first temperature comprises a temperature of up to 180°
F.;further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure. - View Dependent Claims (25, 26)
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27. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step, wherein the first pressure is between about 5 psi and about 10 psi; further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure; wherein the second pressure and temperature comprise a pressure of up to 40 psi and a temperature of up to 230°
F. - View Dependent Claims (28, 29)
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30. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step, wherein the first pressure is between about 5 psi and about 10 psi; further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure and the third temperature is greater than the second temperature; wherein the third pressure and temperature comprise a pressure of up to 92 psi and a temperature of up to 240°
F. - View Dependent Claims (31, 32)
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33. A process of embedding decorative compressible objects within translucent resin sheets by softening and melting the translucent resin sheets about the compressible objects, such that the resultant laminate panel portrays the aesthetic characteristics of the embedded compressible objects, comprising:
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softening a laminate assembly by holding the laminate assembly at a first pressure and heating the laminate assembly at a first temperature until first and second translucent extruded sheets surrounding decorative compressible objects begin to soften and melt around the compressible objects, and do not crush the compressible objects in a first step, wherein the first pressure is between about 5 psi and about 10 psi; further softening and melting the laminate assembly at a second pressure and temperature such that the compressible objects become enveloped by the first and second extruded sheets without being crushed in a second step, wherein the second pressure is greater than the first pressure; and pressing the laminate assembly at a third pressure and temperature, wherein the third pressure is greater than the second pressure; wherein at least one of the first and second extruded sheets comprise extruded poly(ethylene-co-cyclohexane1,4-dimethanol terephthalate) having a thickness of between 0.1 inches and 0.5 inches. - View Dependent Claims (34, 35)
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Specification