Abstract:
In combination, flexible synthetic resinous wicker extending in a first plane, a relatively stiff backer sheet having side thereof intermittently bonded to the wicker to extend in a second plane, generally parallel with the first plane, the backer sheet configured to provide intermittent support to the wicker.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to ornamental or architectural use of wicker formed in a pattern or patterns; and more particularly to provision and support of such wicker production products, enabled by wicker support as in panel configurations. 
     There is perceived need and/or use of attractive wicker in ornamental or architectural modes, as for example on interior walls of buildings and other structures. Wicker is typically flexible, and presents problems of firmly supported application to wall surfaces; for example, wicker is typically formed to have strand crests and crest surfaces, which are difficult to firmly attach to upright walls. 
     SUMMARY OF THE INVENTION 
     It is a major object of the invention to provide means to overcome the above problems and disadvantages and to provide highly useful and efficient solutions to such problems. Basically, the invention provides: 
     a) flexible synthetic resinous wicker extending in a first plane, 
     b) a relatively stiff backer sheet having a side intermittently bonded to the wicker to extend in a second plane, generally parallel with the first plane, 
     c) the backer sheet configured to provide intermittent support to the wicker, and to be attachable to a wall surface. 
     As will be seen, adhesive is applied at intermittent bond locations between the wicker and backer sheet, for example to be cured while the wicker is compression deformed, so as to be tensioned. The wicker typically defines crests facing toward the backer sheet, the adhesive concentrated at surfaces defined by the crests, the wicker being deformed. As a result, the backer sheet and wicker define a laminated composite, the wicker being stiffened and rigidized as the adhesive cures, whereby the composite defines a structural unit to serve as a stiff panel or panels easily assembled against and attachable to a wall. If the wall is deformable, the panels can be attached as by fasteners, during assembly; or, the panel backer surface can be adhesively bonded to the wall. 
     Typically, the backer sheet may consist of one or more of the following:
         i) cementitious material   ii) metallic material   iii) aluminum   iv) magnesium   v) polyurethane       

     Also the adhesive may be polyurethane based. 
     The wicker and backer may consist of thermoplastic material or materials, whereby the composite can be temporarily heated, and deformed into required shape, for wall or other surface covering. 
     Another object is to provide a wicker and backer sheet laminated composite having a selected pattern severed edge portion, the wicker edge portion bonded to a backer sheet edge portion to block unraveling of the wicker at edges of the composite. 
     Yet another object includes provision of a method that includes the following steps:
         i) applying adhesive to a surface of the backer sheet,   ii) applying the wicker to that surface of the backer sheet, so that adhesive on the backer sheet contacts crests formed by the wicker,   iii) and exerting pressure on the wicker directed toward the backer sheet to enhance adhesive attachment of deformed or flattened crests to the backer, while tensioning the wicker to form an integral stabilized wicker panel.       

     Also, the method may include the step of subsequently exerting and maintaining continuous pressure against the wicker and directed toward the backer sheet, during curing of the adhesive to effect bonding. The pressure is sufficient to deform the wicker as at the strand crests, thereby tensioning the wicker for integrating the wicker as it bonds to the backer sheet, thereby to provide a single strong panel wall adapted for application to a wall surface, along with other such panels, in pattern configuration. For example, the steps may include providing first and second such panels which are visibly different, and selectively installing or assembling such visually different wicker panels in architectural relation, as on a wall. 
     A further advantage is that the age-defying, high-performance indoor/outdoor paneling can be made from 100% recyclable, non-toxic and UV-tested wicker fiber, water-resistant and insensitive to the sun, chlorine and harsh weather, its beauty not fading. It may be made in the form of woven panels with laminated backs, formed from 100% post-production recycled materials. It can also be easily modified with carpentry tools. 
     These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood form the following specification and drawings, in which: 
    
    
     
       DRAWING DESCRIPTION 
         FIG. 1  is an elevation showing adhesive application to a backer; 
         FIG. 2  is like  FIG. 1 , but showing application of wicker sheet to the adhesive layers; 
         FIG. 3  is like  FIG. 2 , but showing pressure exertion to the applied wicker; 
         FIG. 4  is an enlarged section showing wicker crests positioned to recess pressure exertion; 
         FIG. 5  is like  FIG. 4 , but showing deflection of pressurized wicker crests, and in relation to adhesive; 
         FIG. 6  shows an alternate mode of pressure application; 
         FIG. 7  is a section showing use of a peel off layer, on the backer; 
         FIGS. 8-11  are elevation views showing different representative forms of wicker that can be used; and 
         FIG. 12  is an elevation showing backed panel composites applied to a wall, with wicker visually extending continuously as it faces toward the viewer. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1 , liquid adhesive is applied by a roller  10  in a thin layer  11  on a surface  12   a  of a backer sheet  12 . That sheet is normally relatively stiff and lightweight, being between about ⅛ and ½ inches thick. The backer may typically consist of one or more of the following:
         i) cementitious material   ii) metallic material   iii) aluminum   iv) magnesium   v) polyurethane       

     The adhesive may be polyurethane based. 
     In  FIG. 2 , a flexible sheet  13  of wicker material is laid on the adhesive, so that the downward facing crests  13   a  and  14   a  of the interwoven warp and woof strands  13  and  14  are in downward contact with the adhesive. In  FIG. 3 , a pusher panel  15  has been applied to the upper side of the wicker material, enabling force F to be applied to the panel for transmission to, and compression deflection of the wicker. 
       FIG. 4  shows the pusher panel  15  touching the upward facing crests  13   b  of the wicker warp strands  13 , the panel  15  also engaging the upward facing crests of the woof strands. 
       FIG. 5  shows the pusher panel  15  having been displaced downwardly by dimension “d”, to compress the wicker as a result of downward compression of warp and woof upper crests. This results in compression of warp and woof downward facing crests,  13   a  and  14   a , and flattening of such crests, indicated at  13   aa  and  14   aa  in  FIG. 5 , to provide significantly greater adhesive contact area with such flattened crests; reduced wicker thickness “t”, take-up of clearances, as at  16  between warp and woof strands, and tightening together of the wicker components, so that after the adhesive is cured, the wicker and backer form a tensioned, cohesive, integral and firm unit or composite.  FIG. 5  shows warp strand  13  engaging woof strand  14 , as at  17 , below crest  13   bb.    
       FIG. 6  shows an alternate means, such as a pressure roller  19 , for exerting downward pressure on the wicker, as the roller is traveled lengthwise over the wicker upper surface. 
       FIG. 7  shows a “peel-off” layer  20 , carried by the backer, so that when the integrated composite is to be applied to a wall surface, layer  20  is removed or peeled-off to expose adhesive  21  on the backer to adhere to the wall surface. 
       FIGS. 8-11  show various wicker attractive configurations  31 - 34  for application with the composites to a wall surface  22 , indicated in  FIG. 12 . As shown, a number of like composites  23  are then applied in edge-to-edge relation to wall surface  22  for enhanced ornamental or architectural effect. Composites  23  may visually differ, as for example as shown in  FIGS. 8-11 . 
     The wicker may take the form of thatch configuration with random oriented strands extending in overlying configuration. 
     The wicker warp and woof strands typically have widthwise flat crest surfaces, the strands having width “2” and thickness “t”, where w&gt;&gt;t. The wicker and backer may have a severed edge portion, the wicker edge portion bonded to backer sheet edge portions to block unraveling of the wicker at edges of the composite.