Patent ID: 7504159
Filing Date: 2009-03-17
Classification: B27D,B32B,B44C,Y10T

Abstract:
1. A method of manufacturing a post-formable decorative resin panel having a unitary sheet of a thin or brittle veneer layer, such that the decorative resin panel is translucent, and such that the veneer layer is not cracked, crushed, or otherwise damaged during the laminating or the thermoforming process, the method comprising: positioning one or more substantially translucent first resin layers on a surface; positioning a unitary, translucent veneer layer of naturally-occurring material about the one or more substantially translucent first resin layers; positioning one or more substantially translucent second resin layers about the at least partially translucent veneer layer, such that at least the one or more first resin layers, the one or more second resin layers, and the at least partially translucent veneer layer form a laminate assembly with opposing viewable outer surfaces defined by the one or more first and second layers; and fusing the laminate assembly at a low pressure, such that the one or more first and one or more second resin layers forming the viewable surfaces melt and adhere to the veneer layer in a manner that the veneer layer material and the first and second resin layers are bendable after fusing, and the resulting combination is at least partially translucent.