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US 11,072,200 B2Granted
Decorative panel having a digitally printed pattern and printing method therefor
AssigneeMaax Bath Inc.
InventorYan Bilodeau
Life of this patent
Estimating the term…
Abstract
Disclosed is a method of producing a pattern for a decorative panel. The method includes applying a clear gel coat on a mold to form a clear layer. The clear layer is cured and then digitally printed with one or more inks so as to produce a pattern on the clear layer. Also disclosed is a decorative panel including a clear layer, an opaque layer and a pattern digitally printed on the clear layer, between the clear and opaque layers, such that the pattern is visible through the clear layer.
Claims26
A method of producing a decorative panel and installing the decorative panel on a surface, the method comprising:
- providing a mold;
- applying a layer of a gel coat on the mold to form a first gelcoat layer, the first gelcoat layer defining a front of the decorative panel;
- curing the first gelcoat layer;
- providing a printer, the printer being operatively coupled to a controller;
- inputting a tridimensional profile of the first gelcoat layer in the controller;
- after curing the first gelcoat layer, printing at least one ink directly onto the cured first gelcoat layer using the printer, the controller adjusting the printing of the at least one ink according to the tridimensional profile of the first gelcoat layer;
- curing the at least one ink printed onto the cured first gelcoat layer;
- after curing the at least one ink printed onto the cured first gelcoat layer, applying a layer of an opaque gel coat on the first gelcoat layer and the at least one ink printed on the first gelcoat layer to form a second gelcoat layer, the at least one ink being sandwiched between the first gelcoat layer and the second gelcoat layer, and wherein the at least one ink is at least partially visible through the first gelcoat layer;
- after forming the second gelcoat layer, curing the second gelcoat layer;
- after curing the second gelcoat layer, applying a reinforcement material on the second gelcoat layer to form a rigid reinforcement layer;
- curing the rigid reinforcement layer;
- after curing the rigid reinforcement layer, removing the mold, thereby obtaining the decorative panel, wherein the front of the decorative panel faces away from the surface when the decorative panel is installed on the surface;
- and
- installing the decorative panel on the surface, wherein the second gelcoat and reinforcing layer are disposed between the first gelcoat layer and the surface.
11 more elements
Dependencies are inferred from the claim text.