Patent Publication Number: US-2003234071-A1

Title: Solid surface wall panel composite and method for making same

Description:
BACKGROUND OF THE INVENTION  
       [0001] 1. Field of the Invention  
       [0002] The present invention relates in general to a method of fabricating a composite panel, and, more particularly, to a method of fabricating a composite panel that includes solid surface material bonded to opposed surfaces of a thermo-set material for easy installation in the walls of bathtubs and/or shower stalls.  
       [0003] 2. Background Art  
       [0004] Wall panel replacement or remodeling has long been known in the art. Due to the cost in panel replacement, alternative wall panels have been developed. Such alternatives include wall panels of solid surface material. Solid surface material possesses numerous properties that make it especially suitable for use in wall panels, including water resistance, fire resistance, scratch resistance, long-term wearability, cleanability, and low maintenance. While wall panels of solid surface material have provided an attractive alternative to wall panel replacement and remodeling, there are nevertheless drawbacks. Notwithstanding their advantageous properties, the solid surface panels, such as wall panels, are formed by a single sheet of material having a thickness, for example, of ¾-inch that is permanently bonded together (laminated) with, for example, a ½-inch solid surface sheet. Such wall panels can be quite heavy, which, in turn, renders them difficult to handle and mount. They are also susceptible to cracking on impact. In addition, several processing steps are required to manufacture such wall panels because solid surface panels are generally formed by sandwiching two sheets of material with an adhesive. Thus, the manufacture of solid surface panels is time-consuming, not to mention costly.  
       [0005] To address the above-discussed deficiencies of the prior art, it is a primary object of this invention to provide a cost-efficient method of fabricating a solid surface composite that requires less processing steps. It is another object of this invention to provide a method of fabricating a solid surface composite that is of decreased thickness and weight as well as increased flexibility.  
       [0006] These and other objects of the present invention will become apparent in view of the present specification, claims and drawings.  
       SUMMARY OF THE INVENTION  
       [0007] The present invention relates to a panel composite sheet, comprising a sheet of solid surface material having a top surface and a bottom surface and a core sheet of material having a top surface and a bottom surface, wherein the top surface of the sheet of solid surface material is bonded to the bottom surface of the core sheet of material. The present invention further comprises a means for bonding the top surface of the solid surface sheet with the bottom surface of the core sheet, wherein the bonding means comprises a material integrally associated with the sheet of solid surface material.  
       [0008] The present invention also relates to a method for forming a panel composite sheet comprising the steps of 1) associating a liquid, solid surface material in a container, 2) mixing a hardening agent with the liquid solid surface material, 3) positioning a bottom surface of a core sheet of material into contact with at least a portion of the liquid solid surface material and hardening agent mixture; 4) hardening the solid surface material; and 5) bonding the bottom surface of the core of material to the top surface of the solid surface material.  
       [0009] The foregoing has outlined rather broadly the features and technical advantages of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they may readily use the conception and the specific embodiment disclosed as a basis for modifying or designing other strictures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.  
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0010] Reference is made to the accompanying drawings in which:  
     [0011]FIG. 1 illustrates an exemplary side-cross sectional view of a panel composite according to the principles of the present invention;  
     [0012]FIG. 2 illustrates an exemplary side-cross sectional view of a liquid, solid surface material that is placed in a container;  
     [0013]FIG. 3 illustrates an exemplary side-cross sectional view of the bottom surface of a core sheet of material positioned into contact with at least a portion of the mixture of liquid, solid surface material and hardening agent; and  
     [0014]FIGS. 4 and 5 schematically illustrate exemplary front and side views, respectively, of an exemplary panel composite according to the principles of the present invention used in association with a wall panel.  
    
    
     BEST MODE FOR PRACTICING THE INVENTION  
     [0015] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will be described in detail, one specific embodiment with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.  
     [0016] Referring initially to FIG. 1, a side-cross sectional view of a panel composite  10  according to the principles of the present invention is shown. Panel composite  10  includes sheet of solid surface material  12  having top surface  14  and bottom surface  16 . Panel composite  10  further includes core sheet  18  having top surface  20  and a bottom surface  22 . As illustrated in FIG. 1, top surface  14  of solid surface sheet  12  is bonded to bottom surface  22  of core sheet  18 . Included in this embodiment is a means for bonding top surface  14  of solid surface sheet  12  with bottom surface  22  of core sheet  18 , such that the bonding means comprises a material integrally associated with solid surface sheet  12 . In a preferred embodiment, the material integrally associated with solid surface sheet  12  is a conventional hardening agent.  
     [0017] In one embodiment, solid surface material  12  is fabricated from any one of a polymer-based material, Corian, avanite and screl. Solid surface materials are conventionally available from various sources, for example, under the trademark CENTURA, available from Centura Solid Surface, Inc. and under the trademark CORIAN, available from DuPont. Those skilled in the art, however, understand that other solid surface materials may also be used to manufacture panel composite  10 .  
     [0018] Solid surface materials provide numerous advantages that are especially beneficial in panel composites including high scratch resistance, long-term wearability, limited maintenance as well as water-resistance and fire-retardance. However, panel composites formed of solid surface material are also quite heavy because panel composites are known to comprise a ½-inch or more sheet of solid surface material that is adhered or laminated to a ¾-inch or more inexpensive sheet of material. Thus, conventional panel composites can be quite heavy and difficult to handle and mount. For this reason, the present invention provides a panel composite of decreased thickness and thus, decreased weight, which provides for a more flexible panel composite. Furthermore, the present invention advantageously provides for a method of fabricating a panel composite of solid surface material that is of decreased thickness and weight, as well as increased flexibility.  
     [0019] Turning now to FIGS. 2 and 3, illustrated is a method for fabricating panel composite  10  according to the principles of the present invention. Referring to FIG. 2, illustrated is a side cross sectional view of mixture  24  of liquid, solid surface material and hardening agent that have been poured into container  26 . Container  26  may be a mold, a jig, or any container capable of housing mixture  24 . Container  26  should be of an appropriate size to provide for the desired length and width of panel composite  10 . In forming panel composite  10  of the present invention, it is advantageous to uniformly mix the hardening agent and the liquid, solid surface material.  
     [0020] As will be described hereinafter, it may be desirable to incorporate various additives and/or filler materials into mixture  24  of the liquid, solid surface material and hardening agent to enhance the properties of panel composite  10 . It is further contemplated that the various additives and/or filler materials may be added into mixture  24  so long as such additives/and or filler materials do not effect the means of bonding core sheet  18  to the solid surface material. Examples of such additives and/or filler materials include a colorant to provide a desired color for panel composite  10 . Also, an agent may be added to increase the flexibility or resiliency of panel composite  10  somewhat so as to better withstand impacts without cracking and enhance resiliency. Thus, the resulting solid surface sheet  12  may comprise a product that is 98 percent de-aired, utilizing a matrix consisting of resins (for example, polyester, acrylic or a combination thereof) and inert fillers, most commonly aluminum trihydrate (ATH), to render the solid surface sheet  12  fire-retardant.  
     [0021] It is further contemplated that, rather than mixing the additives and/or filler materials with the liquid, solid surface material/hardening agent mixture  24  in the container  26 , the additives and/or filler materials may be mixed with the liquid, solid surface material prior to pouring the liquid, solid surface material into container  26 . For example, the additives and/or filler materials may be mixed and homogenized in a vacuum mixer, forcing air from the product (so that the product is 98 percent or better de-aired). After a short mixing cycle, the solid surface material and additives and/or filler materials may then be transferred into container  26  where the hardening agent is then added.  
     [0022] Turning now to FIG. 3, illustrated is an exemplary side-cross-sectional view of bottom surface  22  of core sheet  18  positioned in contact with at least a portion of mixture  24  of the liquid, solid surface material and hardening agent. As illustrated in FIG. 3, a predetermined amount of mixture  24  may be poured into the container  26  such that only a portion  28  of the core sheet  18  is encapsulated by the mixture  24  after core sheet  18  is positioned into mixture  24 . Thus, the amount of the mixture  24  of liquid, solid surface material/hardening agent that is poured into the container depends not only on the desired thickness of the panel composite  10 , but also on the desired portion of the core sheet  18  that is to be encapsulated by the mixture  24 . Alternatively, it is contemplated that the predetermined amount of mixture  24  may be poured into the container  26  such that mixture  24  may be able to encapsulate the entire core sheet  18  after the core sheet  18  is positioned into the mixture  24 . In such embodiments, the solid surface sheet  12  will be on both sides of the core sheet  18  to form a panel composite  10  that may be used, for example, as a wall partition. The material of the core sheet  18  may be comprised of a lightweight material to which the liquid, solid surface material can be effectively bonded. The core sheet  18  may be fabricated from various, usually thermo set materials such as plastic, polyester, acrylic or DR over ABS. Various other materials may also be used to fabricate the core sheet  18  so long as the core sheet may effectively serve as a core for the mixture  24  of liquid, solid surface material/hardening agent. Examples of such materials used to fabricate the core sheet  18  include plywood, fiberglass or aluminum.  
     [0023] In a preferred embodiment, the bonding means comprises a mixture  24  of the hardening agent and the solid surface material in its liquid, ambient state being associated with the bottom surface  22  of the core sheet  18  prior to the hardening of the liquid, solid surface material. Specifically, the liquid, solid surface material hardens before the bottom surface  22  of the core sheet  18  bonds to the top surface  14  of the solid surface sheet  12 . In a preferred embodiment, the bonding means comprises chemically altering the bottom surface  22  of the core sheet  18  by associating the bottom surface  22  of the core sheet  18  with the liquid, solid surface material/hardening agent mixture  24  so as to result in a chemical bond between the solid surface sheet  12  and the core sheet  18 . By bonding the core sheet  18  together with the solid surface material over the entire bottom surface  22  of the core sheet, any chipping or cracking of the solid surface sheet  12  that occurs will not cause other portions of the solid surface sheet  12  to separate from the core sheet  18  and, thus, the integrity of the overall panel composite  10  will effectively be maintained.  
     [0024] The solid surface sheet  12 , in a preferred embodiment, has a thickness from about {fraction (1/16)} inch to about ⅛ inch thick. The core sheet  18  itself preferably has a thickness of about {fraction (1/10)} inch to about ⅛ inch thick. Thus, the present invention advantageously provides for a panel composite  10  having a thickness from about 0.16 to about 0.25 inches It should be understood, however, that although the preferred thickness of the panel composite  10  provides several advantages, the preferred thickness is not intended to limit the panel composite  10  to any particular thickness. Such advantages associated with a thinner panel composite include a panel composite of lighter weight, and thus, a more flexible composite that is easier to handle and mount. In addition to being relatively thin and light in weight, it is also highly shatter-resistant because the core sheet  18  supports the solid surface sheet  12  and functions as a backing for the solid surface sheet  12 . Accordingly, even if the solid surface sheet  12  is to crack or break due to impact, the core sheet  18  maintains the integrity of the overall panel composite  10 .  
     [0025] After the liquid, solid surface material is allowed to bond to the core sheet  18 , the panel composite  10  is demolded or removed from the container  26  and dimensioned to the existing wall by using an appropriate sander like, for example, a drum belt sander. The panel composite  10  may also be fed through a surface sander to fully dimension the system on the solid surface side of the panel composite  10 . As mentioned above, those skilled in the art understand that a second solid surface sheet may be bonded to the core sheet  18  on the other side of the core sheet  18  to provide for a panel composite  10  that may be used, for example, as a wall partition. In such embodiments, the panel composite  10  may be more than ½ inch thick to utilize conventional mounting hardware components and associated installation products.  
     [0026]FIGS. 4 and 5 illustrate front and side views, respectively, of exemplary panel composites used in association with a wall panel according to the principles of the present invention. As illustrated in FIG. 5, the panel composite  10  is dimensioned as to length and width to define a wall  30  between the floor  32  and the ceiling  34 . In other designs, the panel composite may be dimensioned to extend to cover only part of the wall  30 . After the panel composite  10  is demolded or removed from the container  26  and dimensioned to the existing wall  30 , the panel composite  10  may be adhered onto an existing wall  30  using conventional adhesives. If the solid surface sheet  12  should crack or chip, the panel composite  10  may usually be repaired. Superficial damage to the solid surface sheet can usually be repaired by sanding or polishing. For deeper surface damage, a liquid, solid surface liquid material that is formulated to match the solid surface sheet  12  may be used. The resultant product is highly chemical-resistant, stain resistant and repairable and can be tooled into many shapes and designs using conventional tools.  
     [0027] As is known to those skilled in the art, panel composites may be designed in numerous ways, and FIGS. 4 and 5 are only intended to be exemplary of uses. For example, the panel composite may be used as partition panels. In such embodiments, fixtures such as lamps may be mounted to interior walls of the panel composite  10  as desired. Alternatively, the panel composite  10  may be used as an alternative to desktop surfaces. In one embodiment, the panel composite  10  is used as a bathtub or shower stall liner in connection with a bathtub or shower stall. In such uses, the panel composite  10  is removed from the container  26  and dimensioned to an existing bathtub or shower stall to form a bathtub or shower stall liner. The panel composite is then adhered onto the existing bathtub or shower stall liner.  
     [0028] According to the principles of the present invention, a panel composite  10  is provided that has a relatively thin solid surface sheet  12  bonded to an opposed surface of a light-weight core sheet to provide a panel composite  10  with advantageous properties of a solid surface material and, at the same time, provides a relatively thin, light in weight and flexible panel composite. Furthermore, the present invention provides a relatively easy method of manufacturing the panel composite, which is less time consuming and, in turn, more cost efficient.  
     [0029] The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.