# US 11,298,857 B1 · Method of making building panels having simulated wood grain > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,298,857 B1 - Document ID: US11298857B1 - Status: Granted - Kind: B1 - Application number: 16/740,012 - Filed: 2020-01-10 - Granted: 2022-04-12 - Earliest claimed: 2019-01-10 - Assignees: Ferriot Inc. - Applicants: Ferriot Inc. - Inventors: Craig C. Ferriot; Dale H. Leopold - Web page: https://patentgrep.com/patent/US11298857B1 ## CPC - B29C 45/0046: {Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity} - B29C 45/0001: {characterised by the choice of material} - B29C 45/1634: {with a non-uniform dispersion of the moulding material in the article, e.g. resulting in a marble effect} - B29C 45/164: {The moulding materials being injected simultaneously} - B44F 9/02: wood grain effects - E04C 2/20: of plastics - E04C 2/38: with attached ribs, flanges, or the like, e.g. framed panels (concerned with attaching to other panels or elements to form a structure, see the places for the relevant structure, e.g. E04B2/00) - E04F 13/072: composed of specially adapted, structured or shaped covering or lining elements - E04F 13/08: composed of a plurality of similar covering or lining elements, (E04F13/072 takes precedence; borders, skirtings E04F19/02; {of webs or fabrics E04F13/002; fixing strips E04F19/06; separate provisional spacers between adjacent tiles E04F21/0092; implements or means for setting tiles E04F21/18}) - B29C 2045/14155: {using vacuum or suction} - B29C 2045/1698: {multicoloured articles moulded in one step} - B29L 2031/10: Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)} - 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) - B44F: SPECIAL DESIGNS OR PICTURES - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Building panels and methods of making the same are disclosed herein. In one embodiment, a method of injection molding a building panel includes co-mingling a first material and a second material in a molten material, where the second material includes a color that contrasts with the first material. The method also includes injecting the molten material into a cavity of an injection mold, modifying a flow front of the molten material as the molten material flows in the cavity, and cooling the molten material to form a solidified building panel. ## Claims ### Claim 1 A method of injection molding a building panel, comprising: co-mingling a first material and a second material to create a molten material, the second material comprising a color that contrasts with the first material; injecting the molten material into a cavity of an injection mold, wherein the cavity is divided into a first cavity section and a second cavity section, the second cavity section comprising a textured surface simulating wood grain, and wherein the injection mold comprises gate openings through which the molten material flows into the cavity, the gate openings being provided in the first cavity section; applying vacuum pressure within the cavity and thereby modifying a flow of the molten material from within the injection mold while the molten material flows in the injection mold; and cooling the molten material to form a solidified building panel. ### Claim 2 (depends on 1) The method of claim 1, wherein the injection mold comprises at least one vent configured to apply vacuum pressure to an edge of the cavity such that vacuum pressure is applied to the molten material from the edge of the cavity, thereby modifying the flow front of the molten material. ### Claim 3 (depends on 1) The method of claim 1, wherein the injection mold comprises at least one vacuum port through which vacuum pressure is applied to the molten material, thereby modifying the flow front of the molten material. ### Claim 4 (depends on 1) The method of claim 1, wherein the injection mold comprises magnets through which magnetic force is applied to the molten material, thereby modifying the flow front of the molten material. ### Claim 5 (depends on 1) The method of claim 1, wherein the cavity is a pair of cavities and the injection mold further comprises a central vacuum area in between the pair of cavities, wherein vacuum pressure is applied to the molten material through the central vacuum area, thereby modifying the flow front of the molten material. ### Claim 6 (depends on 1) The method of claim 1, wherein the step of co-mingling the first material and the second material in the molten material further includes co-mingling at least a third material having a streaker colorant. ### Claim 7 (depends on 1) The method of claim 1, wherein the first material has a melting point that is less than a melting point of the second material. ### Claim 8 (depends on 7) The method of claim 7, wherein the melting point of the first material is about 20° F. to 70° F. less than the melting point of the second material. ### Claim 9 (depends on 1) The method of claim 1, wherein the first material comprises about 85 wt. % to about 97 wt. % of a base resin. ### Claim 10 (depends on 1) The method of claim 1, wherein the first material comprises a base resin, and the step of co-mingling the first material and the second material further includes co-mingling a third material and a fourth material, wherein the third material is a high melt streaker and the fourth material is a standard melt streaker. ### Claim 11 (depends on 10) The method of claim 10, wherein the third material and the fourth material are blended in a ratio of 30:70 to 70:30. ### Claim 12 (depends on 11) The method of claim 11, wherein the ratio is 50:50. ### Claim 13 (depends on 6) The method of claim 6, wherein the third material is a low melt streaker or a high melt streaker. ### Claim 14 (depends on 1) The method of claim 1, wherein the textured surface extends into at least a portion of first cavity section. ### Claim 15 (depends on 1) The method of claim 1, wherein the ribs are formed formed on the textured surface of the second cavity section. ### Claim 16 (depends on 1) The method of claim 1, wherein a surface of the first cavity section is off-set or oriented at an angle relative to the textured surface of the second cavity section. ### Claim 17 (depends on 1) The method of claim 1, wherein the step of applying vacuum pressure comprises controlling intensity of vacuum pressure, and/or controlling duration of vacuum pressure, and/or controlling start and stop of vacuum pressure. ### Claim 18 (depends on 17) The method of claim 17, wherein vacuum is controlled via a programmable logic controller. ### Claim 19 (depends on 17) The method of claim 17, wherein vacuum is controlled via a timer. ### Claim 20 (depends on 17) The method of claim 17, wherein vacuum is controlled via a switch. ### Claim 21 (depends on 1) The method of claim 1, wherein the step of applying vacuum pressure comprises controlling intensity and/or duration of vacuum pressure.