Decorative panels with recessed patterns and methods of making the same with a flexible die
Assignee3form, Inc.
InventorsCharles H. Moore, Matthew T. Sutton, John E.C. Willham, M. Hoyst Brewster
Life of this patent
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Abstract
Implementations of the present invention relate to decorative thermoplastic resin panels, which can include one or more recesses. The recess of the thermoplastic resin panels can have texture or texture patterns that differ from the texture or texture patterns of non-recessed portions or other recesses of the decorative thermoplastic resin panel. Additionally, the present invention relates to a method for forming recesses in thermoplastic panels with a flexible die.
Claims20
A method of making a decorative thermoplastic panel, comprising:
- preparing panel assembly comprising a thermoplastic resin sheet and a flexible die that has a plurality of flexible protrusions extending from a front surface;
- pressing the flexible die and the thermoplastic resin sheet together, such that one or more flexible protrusions of the plurality of flexible protrusions are in contact with a surface of the thermoplastic resin sheet;
- and
- applying heat to one or more of the flexible die and thermoplastic resin sheet to cause resin of the thermoplastic resin sheet to flow about the flexible protrusions thereby creating a plurality of recesses extending into the surface of the thermoplastic resin sheet.
A decorative thermoplastic panel product comprising a plurality of recesses in a surface thereof, the product having been prepared from a method comprising:
- providing a thermoplastic resin sheet;
- providing a flexible die that has a plurality of flexible protrusions;
- pressing the plurality of flexible protrusions against a surface of the thermoplastic resin sheet;
- and
- applying heat to the thermoplastic resin sheet such that resin of the thermoplastic resin sheet at least partially flows about the flexible protrusions to create a plurality of recesses extending into the surface of the thermoplastic resin sheet;
- wherein one or more recesses of the plurality of recesses are undercut such that the one or more recesses extend beneath a portion of the surface of the thermoplastic resin sheet.
The decorative thermoplastic panel as recited in claim 0, wherein:
- the plurality of recesses have a first texture;
- and
- the surface of the thermoplastic resin sheet has a second texture that differs from the first texture.
(canceled)
A decorative thermoplastic panel, comprising:
- a first surface;
- a second surface opposite to the first surface;
- and
- a plurality of recesses extending into the first surface;
- wherein:
- recesses of the plurality of recesses have a first texture,
- the first surface has a second texture, and
- the second texture differs from the first texture.
Dependencies are inferred from the claim text.