US 9,963,885 B2Granted

Wall panel

AssigneeMax Life, LLC

InventorsCharles David Taylor, Jr., Paul Addison Brown, Berhold Mueller, Randal Hoffner, Stewart Adams

Life of this patent

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Abstract

A wall panel may have a veneer layer, a middle layer made from magnesium oxide and an insulation layer made from a two-part rigid urethane pour foam. The insulation layer maybe chemically bonded to the middle layer. The veneer layer may include a poured substrate made from polyurethane or plastic. The veneer layer may further include aesthetic elements embedded in and bonded to the poured substrate. The aesthetic elements may include one or more of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, or vinyl. A finished surface of the aesthetic elements may extend above a top surface of the poured substrate. The poured substrate may include sand causing the top surface of the poured substrate to have an appearance of mortar.

Claims8

Dependent claims

A wall panel comprising:

a poured substrate selected from the group consisting of polyurethane and plastic;
a middle layer having a first side which is attached to a rear surface of the poured substrate;
an insulation layer having a first side chemically bonded to a second side of the middle layer, and
a plurality of aesthetic elements embedded in and bonded to the poured substrate;
wherein the aesthetic elements are selected from the group consisting of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, and vinyl;
wherein the insulation layer comprises a two part rigid urethane pour foam;
wherein a finished surface of the aesthetic elements extends above a top surface of the poured substrate;
and
wherein each one of the aesthetic elements is in spaced-apart relation to another one of the aesthetic elements.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/297,600Filed 19 Oct 2016 · continuation in part
Priority: 27 Sep 2012
Published: US 2017/0037639 A19 Feb 2017
Granted: 8 May 2018
Term ends: Not estimatedThe source records don’t support an estimate.

Classification24 codes

E04F 13/0875
Composed of a plurality of similar covering or lining elements,: having a basic insulating layer and at least one covering layer
B32B 3/085
Characterised by added members at particular parts: spaced apart pieces on the surface of a layer
B32B 7/08
Interconnection of layers: by mechanical means
B32B 7/12
Interconnection of layers: using interposed adhesives or interposed materials with bonding properties

Family

Application61/706,148Us provisional application · filed 27 Sep 2012
Application14/039,101Parent of this continuation · filed 27 Sep 2013
Application62/245,617Us provisional application · filed 23 Oct 2015
Application15/138,638Parent of this continuation-in-part · filed 26 Apr 2016
US 2017/0037639 A1Pre-grant publication · published 9 Feb 2017
US 9,353,523 B2Parent of this continuation
Application15/138,638Parent of this continuation
US 2014/0083040 A1Published application
US 2016/0237692 A1Published application
US 9,957,722 B2Related patent
US 9,963,885 B2This patent

From the US filing history. Foreign family members aren’t listed.