Patent application number | Description | Published |
20120288694 | RESIN PANELS WITH LARGE DECORATIVE OBJECTS AND METHODS OF MAKING SAME - Implementations of the present invention relate to systems, methods, and apparatus for manufacturing aesthetically pleasing architectural resin panels having a thick three-dimensional interlayer. In particular, at least one implementation includes a layup assembly that includes a decorative interlayer, positioned between resin sheets, that decorative interlayer comprising one or more three-dimensional decorative objects and one or more resin blocks. At least one implementation also includes a single-step lamination or pressing process that uses a combination of heat and pressure to melt the resin sheets and the resin blocks together, forming a decorative resin panel which includes the three-dimensional objects. | 11-15-2012 |
20130149484 | PANELS WITH DECORATIVE OBJECTS AND METHODS OF MAKING THE SAME - Implementations of the present invention relate to systems, methods, and apparatus for embedding objects within thermoplastic resin material and decorative thermoplastic panels resulting therefrom. Implementations include fusing thermoplastic resin particles together to form a decorative resin panel. Furthermore, a manufacturer can place decorative objects within the bed of thermoplastic resin particles to fabricate a decorative resin panel that encapsulates the decorative objects therein. | 06-13-2013 |
20140013691 | STRUCTURED-CORE LAMINATE PANELS AND METHODS OF FORMING THE SAME - A structured-core laminate panel can be made in an efficient, structurally sound manner without the use of adhesives (film or liquid forms) using materials with different melt or glass transition temperatures. In one implementation, a manufacturer positions one or more resin substrates about a structured core, which comprises a relatively high melt or glass transition temperature compared with that of the one or more resin substrates. The manufacturer heats the assembly to at least the glass transition temperature of the resin substrates, but not to the melt or glass transition temperature of the structured core. This allows the one or more resin substrates to melt and bond (mechanically, chemically, or both) to the structured core on one side (or inner surface), while maintaining a substantially planar or original conformation on an opposing side (or outer surface). | 01-16-2014 |
20140065341 | ARCHITECTURAL PANELS INCLUDING ELONGATED THERMOPLASTIC MEMBERS AND METHODS OF MAKING THE SAME - Implementations of the present invention relate to for incorporating virgin or recycled thermoplastic resin materials into architectural thermoplastic panels that have ordered and reproducible geometric patterns. More specifically, at least one implementation provides a method for fusing thermoplastic elongated members, such as circular rods and rectangular bars, sourced from recycled thermoplastic resin to form the architectural thermoplastic panels. | 03-06-2014 |
20140072732 | LAMINATE PANELS PRODUCED FROM BIOPOLYMERS - A method for manufacturing the biopolymer panel may include positioning a plurality of biopolymer sheets adjacent to one another, and subjecting them to a laminating temperature that exceeds the glass-transition temperature of the sheets for a time period sufficient to achieve lamination. The laminate panel is then quenched at a quenching temperature that is below the glass-transition temperature. The time period during lamination, as well as any “rest” period between lamination and quenching, is sufficiently short so as to prevent clouding or hazing as a result of crystallization of the biopolymer resin materials. In addition, the panel exhibits sufficient flame retardency to meet applicable building codes, exhibits sufficient impact resistance for use as a decorative or structural panel building material, and exhibits no substantial thermally induced degradation as a result of subjection to the laminating temperature. The panels may be used as decorative or structural building materials. | 03-13-2014 |
20140199525 | STRUCTURED-CORE LAMINATE PANELS AND METHODS OF FORMING THE SAME - A structured-core laminate panel can be made in an efficient, structurally sound manner, even without the use of adhesives (film or liquid forms) using materials with different melt or glass transition temperatures. In one implementation, a manufacturer positions one or more resin substrates about a structured core member, which comprises a relatively high melt or glass transition temperature compared with that of the one or more resin substrates. The manufacturer heats the assembly to at least the glass transition temperature of the resin substrates, but not to the melt or glass transition temperature of the structured core member. This allows the one or more resin substrates to melt and bond (mechanically, chemically, or both) to the structured core member on one side (or inner surface), while maintaining a substantially planar or original conformation on an opposing side (or outer surface). | 07-17-2014 |
20140215964 | STRUCTURED-CORE LAMINATE PANELS AND METHODS OF FORMING THE SAME - A structured-core laminate panel can be made in an efficient, structurally sound manner without the use of adhesives (film or liquid forms) using materials with different melt or glass transition temperatures. In one implementation, a manufacturer positions one or more resin substrates about a structured core, which comprises a relatively high melt or glass transition temperature compared with that of the one or more resin substrates. The manufacturer heats the assembly to at least the glass transition temperature of the resin substrates, but not to the melt or glass transition temperature of the structured core. This allows the one or more resin substrates to melt and bond (mechanically, chemically, or both) to the structured core on one side (or inner surface), while maintaining a substantially planar or original conformation on an opposing side (or outer surface). | 08-07-2014 |
20140272294 | DECORATIVE PANELS WITH RECESSED PATTERNS AND METHODS OF MAKING THE SAME WITH A FLEXIBLE DIE - 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. | 09-18-2014 |
20140283472 | RESIN PANELS WITH EMBEDDED STRUCTURED-CORES AND METHODS OF MAKING THE SAME - An architectural panel comprises a structured core embedded in a resin material such that the resin material fills the cells of the structured core. In at least one implementation, a method of making the panel comprises pressing two or more resin substrates about the structured core at a pressure and temperature such that the resin substrates flow into and fill the cells of the structured core. In at least one other implementation, a method of making the panel comprises placing the structured core into a form, pouring a liquid resin material into the form, and allowing the resin material to harden. | 09-25-2014 |
20140314896 | PRINTED MOLD AND TEXTURED PANELS FORMED USING THE SAME - Implementations of the present disclosure relate to systems, methods, and apparatus for finishing polymer products and producing one or more designs, textures, and/or embossment patterns on the surface thereof. At least one implementation includes a printed mold that a manufacturer can produce quickly and inexpensively by producing a three-dimensional representation of a two-dimensional image on the surface of a substrate material. The printed mold also can allow the manufacturer to customize designs, textures, and/or embossment patterns on polymer products, while reducing manufacturing costs. | 10-23-2014 |