Decorative multi-layer surfacing materials having embedded conductive materials, solid surfaces made therewith, methods for making such surfacing materials and uses therefor

• US 10,741,322 B2
• Filed: 10/11/2018
• Issued: 08/11/2020
• Est. Priority Date: 10/10/2014
• Status: Active Grant

• Current Assignee: The Diller Corporation
• Original Assignee: The Diller Corporation
• Inventors: O'Brien, Kevin, Cole, Bryce, Kramer, Robert Jacob
• Primary Examiner(s): Borroto, Alfonso Perez
• Application Number:
  US16/157,568
• Publication Number:
  US 20190198224A1
• Time in Patent Office: 670 Days
• Field of Search: 307104
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/20 having particular electrical or magnetic properties, e.g. piezoelectric
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 27/42 comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 7/04 : Interconnection of layers
• CPC Class Codes: H01F 2027/2809 : on stacked layers
• CPC Class Codes: H01F 27/24 : Magnetic cores
• CPC Class Codes: H01F 27/2804 : Printed windings
• CPC Class Codes: H01F 38/14 : Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/041 : Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 5/003 : Printed circuit coils
• CPC Class Codes: H02J 50/10 : using inductive coupling
• CPC Class Codes: H02J 50/12 : of the resonant type
• CPC Class Codes: H02J 50/402 : the two or more transmitting or the two or more receiving devices being integrated in the same unit, e.g. power mats with several coils or antennas with several sub-antennas
• CPC Class Codes: H02J 7/0042 : characterised by the mechanical construction

Abstract

Decorative, multi-layer surfacing materials, surfaces made therewith, methods of making such and wireless power transmission using the same, which surfacing materials comprise: a first resin-impregnated paper layer and a second resin-impregnated paper layer, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus; wherein the first conductive material is disposed on a first surface of the first resin-impregnated paper layer; wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer; and wherein at least one of the first resin-impregnated paper layer, the second resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer.

Claims

1. A decorative, multi-layer surfacing material comprising:

a first resin-impregnated paper layer and a second resin-impregnated paper layer, an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus;

wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed relationship such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer;

wherein the enhancement layer is disposed and cured between the first conductive material and one of the first and second resin impregnated layers; and

wherein at least one of the first resin-impregnated paper layer, the second resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer.

2. The decorative, multi-layer surfacing material according to claim 1, further comprising at least one outer protective layer.

3. The decorative, multi-layer surfacing material according to claim 2, wherein the at least one outer protective layer comprises a polymer selected from the group consisting of acrylics, polyesters, melamine resins, vinyl resins, and urethanes.

4. The decorative, multi-layer surfacing material according to claim 2, wherein the at least one outer protective layer comprises a melamine resin.

5. The decorative, multi-layer surfacing material according to claim 1, wherein the decorative layer comprises a visual attribute selected from the group consisting of colorings, patterns, indicia, pictures, embedded objects, and combinations thereof.

6. The decorative, multi-layer surfacing material according to claim 1, wherein the first conductive material disposed on the first surface of the first resin-impregnated paper layer is patterned.

7. The decorative, multi-layer surfacing material according to claim 6, wherein the patterned first conductive material comprises a continuous meandering line selected from the group consisting of spirals, spirangles, sawtooth waves and combinations thereof.

8. A decorative, multi-layer surfacing material according to claim 1, further comprising a third resin-impregnated paper layer and a second conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus, wherein the second conductive material is disposed on a second surface of the of the first resin-impregnated paper layer, wherein the second surface is on a side of the first resin-impregnated paper layer opposite of the first surface, and wherein the first resin-impregnated paper layer and the third resin-impregnated paper layer are disposed in a stacked and compressed relationship such that the second conductive material is encapsulated between the first resin-impregnated paper layer and the third resin-impregnated paper layer.

9. The decorative, multi-layer surfacing material according to claim 1, wherein the first conductive material and the second conductive material are conductively connected through the first resin-impregnated paper layer.

10. The decorative, multi-layer surfacing material according to claim 9, further comprising a third conductive material having a first terminus and a second terminus and capable of carrying an electric current, wherein the third conductive material is disposed on a first surface of the second resin-impregnated paper layer, wherein the third conductive material is in a facing relationship with the first conductive material, wherein the resin impregnating the first and second paper layers comprises a thermoset resin, and wherein an additional layer selected from the group consisting of an interposed resin-impregnated paper layer, an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, and combinations thereof, is disposed and cured between the first conductive material and the third conductive material.

11. The decorative, multi-layer surfacing material according to claim 10, wherein the first conductive material and the third conductive material are conductively connected through the additional layer.

12. The decorative, multi-layer surfacing material according to claim 1, further comprising a first conductive protrusion and a second conductive protrusion extending from the first terminus and second terminus of the first conductive material, respectively, to two positions along a periphery of the surfacing material and configured such that an external electrical current can be supplied to the conductive protrusion.

13. The decorative, multi-layer surfacing material according to claim 1, further comprising a circuit component disposed on the first surface of the first resin-impregnated paper layer and in conductive contact with the first conductive material.

14. The decorative, multi-layer surfacing material according to claim 1, wherein the material is a high pressure laminate.

15. A solid surface comprising the decorative, multi-layer surfacing material according to claim 1 disposed on a supporting substrate.

16. A decorative, multi-layer surfacing material comprising:

a first resin-impregnated paper layer and a second resin-impregnated paper layer, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus;

wherein the first conductive material comprises a conductive ink;

wherein the first conductive material is disposed on a first surface of the first resin-impregnated paper layer;

wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed relationship such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer, further comprising a third resin-impregnated paper layer and a second conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus;

wherein the second conductive material is disposed on a second surface of the first resin-impregnated paper layer;

wherein the second surface is on a side of the first resin-impregnated paper layer opposite of the first surface;

wherein the first resin-impregnated paper layer and the third resin-impregnated paper layer are disposed in a stacked and compressed relationship such that the second conductive material is encapsulated between the first resin-impregnated paper layer and the third resin-impregnated paper layer; and

wherein at least one of the first resin-impregnated paper layer, the third resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer.

17. The decorative, multi-layer surfacing material according to claim 16, further comprising at least one outer protective layer.

18. The decorative, multi-layer surfacing material according to claim 17, wherein the at least one outer protective layer comprises a polymer selected from the group consisting of acrylics, polyesters, melamine resins, vinyl resins, and urethanes.

19. The decorative, multi-layer surfacing material according to claim 17, wherein the at least one outer protective layer comprises a melamine resin.

20. The decorative, multi-layer surfacing material according to claim 16, wherein the decorative layer comprises a visual attribute selected from the group consisting of colorings, patterns, indicia, pictures, embedded objects, and combinations thereof.

21. The decorative, multi-layer surfacing material according to claim 16, wherein the first conductive material disposed on the first surface of the first resin-impregnated paper layer is patterned.

22. The decorative, multi-layer surfacing material according to claim 21, wherein the patterned first conductive material comprises a continuous meandering line selected from the group consisting of spirals, spirangles, sawtooth waves and combinations thereof.

23. The decorative, multi-layer surfacing material according to claim 16, wherein the first conductive material and the second conductive material are conductively connected through the first resin-impregnated paper layer.

24. The decorative, multi-layer surfacing material according to claim 16, further comprising an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, the enhancement layer disposed and cured between one of the first and second conductive materials and an adjacent resin impregnated layer.

25. The decorative, multi-layer surfacing material according to claim 23, further comprising a third conductive material having a first terminus and a second terminus and capable of carrying an electric current, wherein the third conductive material is disposed on a first surface of the second resin-impregnated paper layer, wherein the third conductive material is in a facing relationship with the first conductive material, wherein the resin impregnating the first and second paper layers comprises a thermoset resin, and wherein an additional layer selected from the group consisting of an interposed resin-impregnated paper layer, an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, and combinations thereof, is disposed and cured between the first conductive material and the third conductive material.

26. The decorative, multi-layer surfacing material according to claim 25, wherein the first conductive material and the third conductive material are conductively connected through the additional layer.

27. The decorative, multi-layer surfacing material according to claim 16, further comprising a first conductive protrusion and a second conductive protrusion extending from the first terminus and second terminus of the first conductive material, respectively, to two positions along a periphery of the surfacing material and configured such that an external electrical current can be supplied to the conductive protrusion.

28. The decorative, multi-layer surfacing material according to claim 16, further comprising a circuit component disposed on the first surface of the first resin-impregnated paper layer and in conductive contact with the first conductive material.

29. The decorative, multi-layer surfacing material according to claim 16, wherein the material is a high pressure laminate.

30. A solid surface comprising the decorative, multi-layer surfacing material according to claim 16 disposed on a supporting substrate.