Architectural panels with objects embedded in resin interlayer

• US 8,241,714 B2
• Filed: 12/13/2011
• Issued: 08/14/2012
• Est. Priority Date: 09/01/2004
• Status: Active Grant

• Current Assignee: 3Form (Hunter Douglas N.V.)
• Original Assignee: 3Form (Hunter Douglas N.V.)
• Inventors: Adickes, Eric M.
• Primary Examiner(s): SPEER, TIMOTHY M
• Application Number:
  US13/324,949
• Publication Number:
  US 20120088042A1
• Time in Patent Office: 245 Days
• Field of Search: None
• US Class Current: 428/13
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10247 Laminated safety glass or glazing containing decorations or patterns for aesthetic reasons containing metal wires for aesthetic reasons B32B17/10422
• CPC Class Codes: B32B 17/10917 between two pre-positioned glass layers
• CPC Class Codes: B44C 5/005 comprising inserts
• CPC Class Codes: B44C 5/0407 containing glass elements
• CPC Class Codes: Y10T 428/22 Nonparticulate element embedded or inlaid in substrate and visible
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/239 Complete cover or casing

Abstract

A decorative architectural glass panel comprises a two or more glass sheets separated by a resin in which one or more decorative objects are suspended. A method of making the glass panel comprises positioning one or more spacers and one or more decorative objects on a first glass sheet, placing a second glass sheet about the first glass sheet, sealing the edges of the first glass sheet and second glass sheet, and filling the space between the first and second glass sheets with a curable liquid resin. The resin can be poured using a substantially horizontal pour in order to keep the decorative objects from substantially shifting when pouring the liquid resin. The resin can also be poured in combination with a vacuum force. In some implementations, the glass panel may also be substituted with a resin panel using polymeric resin sheets.

Claims

1. A decorative architectural panel having decorative objects embedded therein comprising:

a first transparent sheet positioned opposed to a second transparent sheet in a registered fashion;

a hardened resin between the first and second transparent sheets; and

a plurality of discrete decorative objects spaced apart in the solidified resin between the first and second transparent sheets,

wherein;

the plurality of decorative objects are fixedly arranged throughout the solidified resin,

decorative objects of the plurality of decorative objects are positioned throughout the area between the peripheral edges of the first and second transparent sheets and thereby occlude the panel, and

the decorative objects of the plurality of decorative objects are suspended in the solidified resin between the first and second transparent sheets.

2. The decorative architectural panel as recited in claim 1, further comprising decorative objects that appear to be uncompressed from a natural state.

3. The decorative architectural panel as recited in claim 1, wherein the solidified resin is a gelled resin.

4. The decorative architectural panel as recited in claim 1, wherein the first and second transparent sheets comprise glass.

5. The decorative architectural panel as recited in claim 1, wherein the first and second transparent sheets comprise resin.

6. The decorative architectural panel as recited in claim 5, wherein the resin of the first and second transparent sheets comprises a resin material differing from the resin material of the solidified resin.

7. The decorative architectural panel as recited in claim 1, wherein the first and second transparent sheets are flexible.

8. The decorative architectural panel as recited in claim 1, wherein decorative objects of the plurality of decorative objects comprise organic objects.

9. The decorative architectural panel as recited in claim 8, further comprising a UV-curable resin coated on the plurality of decorative objects, the UV-curable resin differing from the solidified resin.

10. An architectural panel for use in an architectural design environment comprising:

a first transparent sheet;

an opposing second sheet secured to the first transparent sheet by a layer of solidified resin; and

a plurality of organic objects suspended in the solidified resin between the first transparent sheet and the second sheet, wherein organic objects of the plurality of organic objects are positioned throughout the area between the peripheral edges of the first and second transparent sheets and thereby occlude the panel.

11. The panel as recited in claim 10, wherein the plurality of organic objects comprise one or more of vegetative fruits, rocks, minerals, crystals, vegetative brush, branches, thatch, grass, leaves, bamboo, or reed.

12. The panel as recited in claim 10, wherein the organic objects have a substantially two-dimensional configuration.

13. The panel as recited in claim 10, wherein the organic objects have a substantially three-dimensional configuration.

14. The panel as recited in claim 10, further comprising a UV-curable resin coated on the plurality of organic objects, the UV-curable resin differing from the layer of solidified resin.

15. The panel as recited in claim 10, further comprising one or more air bubbles positioned within the layer of solidified resin.

16. In an internal architectural environment, a panel, comprising:

a first transparent sheet;

a second transparent sheet;

a solidified resin positioned between the first and second transparent sheets, the solidified resin securing the first and second transparent sheets together; and

a plurality of discrete decorative objects arranged throughout the solidified resin between the first and second transparent sheets,

wherein decorative objects of the plurality of decorative objects;

are positioned throughout the area between the peripheral edges of the first and second transparent sheets and thereby occlude the panel, and

are suspended in the solidified resin between the first and second transparent sheets.

17. The panel as recited in claim 16, wherein the solidified resin has a thickness of between about ⅛

of an inch and about ½

of an inch.

18. The panel as recited in claim 16, wherein the first and second transparent sheets each comprise a polymeric resin selected from the group consisting of polyester resin, polycarbonate resin, acrylic resin, and mixtures thereof.

19. The panel as recited in claim 18, wherein the polymeric resin of the first and second transparent sheets differs from the solidified resin.

20. The panel as recited in claim 16, wherein the plurality of discrete decorative objects comprise synthetic, manufactured, or naturally-occurring representations of vegetative fruits, rocks, minerals, crystals, vegetative brush, branches, thatch, grasses, or willow reed.

21. A decorative architectural panel having decorative objects embedded therein comprising:

a first transparent sheet;

a second transparent sheet;

a resin interlayer between the first and second transparent sheets; and

a plurality of discrete decorative objects spaced apart in the resin interlayer between the first and second transparent sheets,

wherein;

the plurality of decorative objects are fixedly arranged throughout the resin interlayer,

decorative objects of the plurality of decorative objects are positioned throughout the area between the peripheral edges of the first and second transparent sheets and thereby occlude the panel, and

the decorative objects of the plurality of decorative objects are suspended in the resin interlayer between the first and second transparent sheets.

22. The decorative architectural panel as recited in claim 21, wherein the resin interlayer is a polymerized resin.

23. The decorative architectural panel as recited in claim 21, wherein the resin interlayer is a cured resin.

24. The decorative architectural panel as recited in claim 21, wherein the first and second transparent sheets comprise glass.

25. The decorative architectural panel as recited in claim 21, wherein the first and second transparent sheets comprise resin.

26. The decorative architectural panel as recited in claim 25, wherein the resin of the first and second transparent sheets differs from the resin of the resin interlayer.

27. The decorative architectural panel as recited in claim 21, wherein decorative objects of the plurality of decorative objects comprise organic objects.

28. The decorative architectural panel as recited in claim 27, wherein the organic objects comprise one or more of vegetative fruits, rocks, minerals, crystals, vegetative brush, branches, thatch, grass, leaves, bamboo, or reed.

29. The decorative architectural panel as recited in claim 21, wherein:

each of the first and second transparent sheets comprises a first surface, an opposing second surface, and a thickness extending between the first and second surfaces;

the first surface of each of the first and second transparent sheets form outer surfaces of the decorative architectural panel; and

the resin interlayer is positioned between the second surface of the first transparent sheet and the second surface of the second transparent sheet.

30. The decorative architectural panel as recited in claim 29, wherein the first and second transparent sheets comprise glass.

31. The decorative architectural panel as recited in claim 29, wherein the resin interlayer has a thickness of between about ⅛

of an inch and about ½

of an inch.

32. The decorative architectural panel as recited in claim 31, wherein:

the thickness of the first transparent sheet is between about 1/16 of an inch and about ½

of an inch; and

the thickness of the second transparent sheet is between about 1/16 of an inch and about ½

of an inch.

33. The decorative architectural panel as recited in claim 32, wherein decorative objects of the plurality of decorative objects comprise one or more of vegetative fruits, rocks, minerals, crystals, vegetative brush, branches, thatch, grass, leaves, bamboo, or reed.