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US 9,809,054 B2Granted
Decorated rigid panel
AssigneeKohler Co.
InventorsSteven Grunwald, Jonathan Kyle, Robert D. Hill
Life of this patent
Estimating the term…
Abstract
A panel includes a thermoset material, and an image comprising sublimation ink. The sublimation ink is absorbed in the thermoset material. The rigid component may be a rigid structure formed by the thermoset material. The panel may be for a bath or shower enclosure.
Claims16
A modular shower wall, comprising:
- a rigid panel for use as a wall in a shower enclosure, the rigid panel formed from a substrate material;
- and
- an image on a surface of the rigid panel, the image comprising sublimation ink absorbed in the substrate material;
- wherein the substrate material is a charge comprising a first outer layer of a homogeneous paste material, a plurality of glass fibers disposed over the first outer layer, and a second outer layer of the homogeneous paste material disposed over the plurality of glass fibers;
- wherein the charge is folded a plurality of times to define a multi-layer charge having a smaller width and length than the width and length of the rigid panel;
- and
- wherein outer surfaces of the multi-layer charge do not include an additional material layer formed thereon and in which the sublimation ink is absorbed.
4 more elements
A modular panel for a shower enclosure, comprising:
- a thermoset material forming a rigid panel for use in a shower enclosure;
- and
- an image on a surface of the rigid panel, the image comprising sublimation ink absorbed in the thermoset material;
- wherein the rigid panel is formed by compression molding the thermoset material between an upper tool heated to a first temperature and a lower tool heated to a second temperature that is less than the first temperature, so as to facilitate curing of the thermoset material and to achieve a desired surface aesthetic of the rigid panel;
- wherein the thermoset material is charge comprising a first outer layer of a homogeneous paste material, a plurality of glass fibers disposed over the first outer layer, and a second outer layer of the homogeneous paste material disposed over the plurality of glass fibers;
- wherein the charge is folded a plurality of times to define a multi-layer charge having a smaller width and length than the width and length of the rigid panel;
- and
- wherein outer surfaces of the multi-layer charge do not include an additional material layer formed thereon and in which the sublimation ink is absorbed.
5 more elements
A shower enclosure, comprising:
- a plurality of modular panels configured to be coupled to each other to define an enclosure;
- wherein one or more of the plurality of modular panels comprises:
- a thermoset material forming a panel;
- and
- an image on a surface of the panel, the image comprising sublimation ink absorbed in the thermoset material;
- wherein the thermoset material is a charge comprising a first outer layer of a homogeneous paste material, a plurality of glass fibers disposed over the first outer layer, and a second outer layer of the homogeneous paste material disposed over the plurality of glass fibers;
- wherein the charge is folded a plurality of times to define a multi-layer charge having a smaller width and length than the width and length of the panel;
- and
- wherein outer surfaces of the multi-layer charge do not include an additional material layer formed thereon and in which the sublimation ink is absorbed.
6 more elements
Dependencies are inferred from the claim text.