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US 10,377,065 B1Granted
Method for producing building panels by making coated foam in situ in a mold
AssigneeBoral IP Holdings (Australia) PTY Limited
InventorRussell Hill
Life of this patent
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Abstract
Disclosed herein are composite building materials having at least one textured surface. The textured surface includes at least a plurality of particles. The textured surface closely mimics conventional building materials. The building materials can contain an image printed using ink jet printing methods with inks optimized for enhanced color stability.
Claims40
A building material comprising:
- a composite comprising:
- (a) a polymeric substrate comprising a foam formed from a composition comprising:
- at least one polyol;
- at least one isocyanate reactive with the at least one polyol;
- and
- an inorganic filler;
- and
- (b) a textured surface in contact with the polymeric substrate, the textured surface comprising:
- a binder;
- and
- a plurality of particles having an average particle size of less than or equal to about 10 μm;
- wherein the binder comprises functional groups chemically bonded to the polymeric substrate;
- wherein the plurality of particles has a chemical composition different from a chemical composition of the inorganic filler of the foam;
- and
- wherein at least a portion of the plurality of particles is embedded in the foam, and at least a portion of the plurality of particles protrudes from the textured surface.
12 more elements
A composite panel comprising:
- a polymeric substrate comprising a foam formed from a composition comprising at least one polyol, at least one isocyanate, and an inorganic filler;
- and
- a first textured surface comprising a first binder and a first plurality of particles;
- wherein the first binder of the first textured surface is chemically bonded to the polymeric substrate;
- wherein at least a portion of the first plurality of particles is embedded in the foam, and at least a portion of the first plurality of particles protrudes from the first textured surface;
- and
- wherein the first textured surface includes an image printed in ink thereon, the ink comprising an inorganic pigment.
4 more elements
A composite panel comprising:
- a polymeric substrate comprising a foam formed from a composition comprising at least one polyol, at least one isocyanate, and an inorganic filler;
- and
- a first textured surface chemically bonded to the substrate, the first textured surface comprising a first binder and a first plurality of particles having an average particle size of less than or equal to 10 μm the first textured surface including an image printed thereon with an ink comprising an inorganic pigment;
- wherein the first binder of the first textured surface is chemically bonded to the polymeric substrate via functional groups of the first binder, the first plurality of particles being dispersed within the binder;
- wherein the first plurality of particles has a chemical composition different from a chemical composition of the inorganic filler of the foam;
- and
- wherein at least a portion of the first plurality of particles is embedded in the foam, and at least a portion of the plurality of particles protrudes from the first textured surface.
4 more elements
Dependencies are inferred from the claim text.