# US 10,479,054 B2 · Patterned composite product > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,479,054 B2 - Document ID: US10479054B2 - Status: Granted - Kind: B2 - Application number: 13/124,799 - Filed: 2009-10-20 - Published: 2011-10-27 - Granted: 2019-11-19 - Earliest claimed: 2008-10-20 - Assignees: Acell Industries Limited - Applicants: Aldino Albertelli; Michael Frieh - Inventors: Aldino Albertelli; Michael Frieh - Web page: https://patentgrep.com/patent/US10479054B2 ## CPC - B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs - B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)} - B29C 70/78: Moulding material on one side only of the preformed part - B32B 27/065: {of foam} - B32B 27/12: next to a fibrous or filamentary layer - B44C 5/0453: {produced by processes involving moulding} - B29K 2105/043: {Skinned foam} - B32B 2266/06: Open cell foam - B32B 2305/022: Foam - B32B 2305/20: in the form of a non-woven mat - B32B 2305/72: Cured, e.g. vulcanised, cross-linked - B32B 2315/085: Glass fiber cloth or fabric - Y10T 156/1041: Subsequent to lamination - Y10T 428/2481: including layer of mechanically interengaged strands, strand-portions or strand-like strips - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material. ## Claims ### Claim 1 A method for forming a composite product having a patterned surface, the method comprising: providing a substrate having a substantially open-celled structure; providing a sheet comprising curable material; providing a printed patterned sheet; then applying the sheet comprising curable material and the printed patterned sheet to a surface of the substrate; and applying pressure to cause the sheet comprising curable material to pass into the surface of the substrate and at least substantially through the thickness of the printed patterned sheet in order to form the composite product. ### Claim 2 (depends on 1) The method of claim 1, wherein the sheet comprising curable material is applied between the substrate and the printed patterned sheet. ### Claim 3 (depends on 1) The method of claim 1, wherein the application of pressure is facilitated by a mould, wherein the printed patterned sheet is provided between the sheet comprising curable material and a surface of the mould. ### Claim 4 (depends on 1) The method of claim 1, further comprising curing the curable material of the sheet. ### Claim 5 (depends on 1) The method of claim 1, wherein the printed patterned sheet comprises a non-woven material. ### Claim 6 (depends on 1) The method of claim 1, wherein the printed patterned sheet comprises a glass veil. ### Claim 7 (depends on 1) The method of claim 1, wherein the printed patterned sheet has a weight of less than 200 g/m2. ### Claim 8 (depends on 1) The method of claim 1, wherein the printed patterned sheet is printed by an inkjet printer. ### Claim 9 (depends on 1) The method of claim 1, wherein, prior to the application of pressure, the sheet comprising curable material is arranged such that the curable material is substantially continuous across the surface of the printed patterned sheet. ### Claim 10 (depends on 1) The method of claim 1, wherein prior to the application of pressure, the sheet comprising curable material is arranged to extend across the surface of the printed patterned sheet. ### Claim 11 (depends on 1) The method of claim 1, wherein the sheet comprising curable material includes a thermosetting material. ### Claim 12 (depends on 1) The method of claim 1, wherein the sheet comprising curable material includes reinforcing fibres. ### Claim 13 (depends on 1) The method of claim 1, wherein the sheet comprising curable material comprises sheet moulding compound (SMC). ### Claim 14 (depends on 1) The method of claim 1, wherein sheet comprising curable material includes an impregnated fibre composite material. ### Claim 15 (depends on 1) The method of claim 1, wherein the substrate comprises a crushable material to cause the surface of the substrate to mould during the application of pressure. ### Claim 16 (depends on 1) The method of claim 1, wherein the printed patterned sheet is formed by printing at least a portion of a prepared image onto a surface of a sheet to form the pattern. ### Claim 17 (depends on 1) The method of claim 1, further comprising providing at least one other printed patterned sheet to form a set of printed patterned sheets, wherein each pattern within the set forms at least a portion of a larger image. ### Claim 18 (depends on 1) The method of claim 1, wherein the printed patterned sheet has a weight of less than 150 g/m2.