U.S. patent application number 14/235851 was filed with the patent office on 2014-06-19 for decorative insulative products for construction.
This patent application is currently assigned to Owens Corning Intellectual Capital, LLC. The applicant listed for this patent is Mihai Gavris, Tiberius Ioan Oltean. Invention is credited to Mihai Gavris, Tiberius Ioan Oltean.
Application Number | 20140170365 14/235851 |
Document ID | / |
Family ID | 47668741 |
Filed Date | 2014-06-19 |
United States Patent
Application |
20140170365 |
Kind Code |
A1 |
Gavris; Mihai ; et
al. |
June 19, 2014 |
DECORATIVE INSULATIVE PRODUCTS FOR CONSTRUCTION
Abstract
A decorative, insulative product configured for application to
the interior or exterior surfaces of a building structure is
provided. The product includes one or more layers configured to
form a rigid, puncture resistant outer protective surface for the
product and a base layer configured to support the one or more
layers. The one or more layers forming the outer surface of the
product are configured to provide a desired aesthetic appearance to
the building or structure and the base layer is configured to
provide a thermal insulative value and an acoustic insulative value
to the product.
Inventors: |
Gavris; Mihai; (Cluj-Napoca,
RO) ; Oltean; Tiberius Ioan; (Turda, RO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gavris; Mihai
Oltean; Tiberius Ioan |
Cluj-Napoca
Turda |
|
RO
RO |
|
|
Assignee: |
Owens Corning Intellectual Capital,
LLC
Toledo
OH
|
Family ID: |
47668741 |
Appl. No.: |
14/235851 |
Filed: |
August 10, 2011 |
PCT Filed: |
August 10, 2011 |
PCT NO: |
PCT/US11/47219 |
371 Date: |
March 5, 2014 |
Current U.S.
Class: |
428/71 ; 264/255;
428/141; 428/304.4; 428/319.7 |
Current CPC
Class: |
Y10T 428/233 20150115;
E04F 13/185 20130101; E04F 13/0876 20130101; E04F 13/0875 20130101;
Y10T 428/249992 20150401; Y10T 428/249953 20150401; Y10T 428/24355
20150115; E04B 1/88 20130101 |
Class at
Publication: |
428/71 ;
428/304.4; 428/319.7; 428/141; 264/255 |
International
Class: |
E04B 1/88 20060101
E04B001/88; E04F 13/08 20060101 E04F013/08 |
Claims
1. A decorative, insulative product configured for application to
an interior or exterior wall of a building structure, the product
comprising: one or more layers configured to form a rigid, puncture
resistant outer protective surface for the product; and a base
layer co-molded with and configured to support the one or more
layers forming the outer protective surface; wherein the one or
more layers forming the outer protective surface covers an entire
front face of the base layer; wherein the one or more layers
forming the outer surface of the product are configured to provide
a desired aesthetic appearance to the building or structure; and
wherein the base layer is configured to provide a thermal
insulative value and an acoustic insulative value to the
product.
2. The product of claim 1, wherein the one or more layers forming
the outer protective surface are formed from unsaturated
polymeric-based materials.
3. (canceled)
4. (canceled)
5. The product of claim 1, wherein the one or more layers forming
the outer protective surface have a thickness in a range of from
about 0.02 inches (0.5 mm) to about 0.44 inches (11.2 mm).
6. The product of claim 1, wherein the one or more layers are
configured to have a textured surface that simulates a plurality of
natural stones.
7. The product of claim 1, wherein the base layer is formed from
polymeric-based foam materials.
8. The product of claim 1, wherein the base layer has an average
thickness in a range of from about 0.59 inches (15.0 mm) to about
11.8 inches (300.0 mm).
9. The product of claim 1, wherein the base layer provides an
insulative value (R) of 20 at an average thickness of 0.79 inches
(20.0 mm).
10. The product of claim 1, wherein the base layer and the one or
more layers forming the outer surface combine to product a noise
reduction coefficient in a range of from about 0.2 to about
0.7.
11. A method of manufacturing a decorative, insulative product
configured for application to the interior or exterior surfaces of
a building structure, the method comprising the steps of: forming
one or more layers within a mold, the one or more layers configured
to form a rigid, puncture resistant outer protective surface for
the product; and applying a base layer in the mold over the one or
more layers configured to support the one or more layers; wherein
the one or more layers forming the protective outer surface covers
an entire front face of the base layer; wherein the one or more
layers forming the outer surface of the product are configured to
provide a desired aesthetic appearance to the building or
structure; and wherein the base layer is configured to provide a
thermal insulative value and an acoustic insulative value to the
product.
12. The method of claim 11, wherein the one or more layers forming
the outer protective surface are formed from unsaturated
polymeric-based materials.
13. (canceled)
14. (canceled)
15. The method of claim 11, wherein the one or more layers forming
the outer protective surface have a thickness in a range of from
about 0.02 inches (0.5 mm) to about 0.44 inches (11.2 mm).
16. The method of claim 11, wherein the one or more layers are
configured to have a textured surface that simulates a plurality of
natural stones.
17. The method of claim 11, wherein the base layer is formed from
polymeric-based foam materials.
18. The method of claim 11, wherein the base layer has an average
thickness in a range of from about 0.59 inches (15.0 mm) to about
11.8 inches (300.0 mm).
19. The product of claim 11, wherein the base layer provides an
insulative value (R) of 20 at an average thickness of 0.79 inches
(20.0 mm).
20. A building wall covered with decorative, insulative product,
the building wall comprising: a plurality of framing members
forming an exterior or interior surface; and a plurality of
decorative, insulative product covering the exterior or interior
surface formed by the framing members, the decorative, insulative
product including one or more layers configured to form a rigid,
puncture resistant outer protective surface for the product and a
base layer co-molded and configured to support the one or more
layers forming the outer protective surface; wherein the one or
more layers forming the outer protective surface covers an entire
front face of the base layer; wherein the one or more layers
forming the outer surface of the product are configured to provide
a desired aesthetic appearance to the exterior or interior surface
of the building wall; and wherein the base layer is configured to
provide a thermal insulative value and an acoustic insulative value
to the product.
21. The building wall of claim 20 wherein the outer protective
surface covers the top edge and the bottom edge of the base
layer.
22. The product of claim 1 wherein the outer protective surface
covers a top edge and a bottom edge of the base layer.
23. The method of claim 11 wherein the outer protective surface
covers a top edge and a bottom edge of the base layer.
Description
BACKGROUND
[0001] The exterior and interior surfaces of a building can be
covered by many materials including natural materials, manufactured
materials and materials simulating natural or manufactured
materials. Non-limiting examples of natural materials include wood
and stone. Non-limiting examples of manufactured materials include
siding, stucco and masonry. Examples of materials simulating
natural and manufactured materials include simulated stone,
simulated wood, simulated siding, simulated stucco and simulated
brick.
[0002] The exterior coverings of a building are configured to repel
weather elements and protect the interior of the building or
structure from the effects of weather. Additionally, the exterior
and interior coverings of a building can present a desired
aesthetic appearance to the building or structure.
[0003] Simulated materials can take many forms including the
non-limiting examples of individual pieces or panels formed to
represent the combination of individual pieces. Simulated materials
can be applied to various types of building structures. Some
examples of building structures configured to support simulated
materials include wood or metal framing members (studs) or framing
members covered by layers of sheet material (sheathing) and
subsequently covered by one or more layers of insulation.
[0004] It would be advantageous if simulated materials could be
improved.
SUMMARY OF THE INVENTION
[0005] The above objects as well as other objects not specifically
enumerated are achieved by a decorative, insulative product
configured for application to the interior or exterior surfaces of
a building structure. The product includes one or more layers
configured to form a rigid, puncture resistant outer protective
surface for the product and a base layer configured to support the
one or more layers. The one or more layers forming the outer
surface of the product are configured to provide a desired
aesthetic appearance to the building or structure and the base
layer is configured to provide a thermal insulative value and an
acoustic insulative value to the product.
[0006] According to this invention there is also provided a method
of manufacturing a decorative, insulative product configured for
application to the interior or exterior surfaces of a building
structure. The method includes the steps of forming one or more
layers within a mold, the one or more layers configured to form a
rigid, puncture resistant outer protective surface for the product
and applying a base layer over the one or more layers configured to
support the one or more layers. The one or more layers forming the
outer surface of the product are configured to provide a desired
aesthetic appearance to the building or structure and the base
layer is configured to provide a thermal insulative value and an
acoustic insulative value to the product.
[0007] According to this invention there is also provided a
building wall covered with decorative, insulative product. The
building wall includes a plurality of framing members forming an
exterior or interior surface and a plurality of decorative,
insulative product covering the exterior or interior surface formed
by the framing members. The decorative, insulative product includes
one or more layers configured to form a rigid, puncture resistant
outer protective surface for the product and a base layer
configured to support the one or more layers forming the outer
protective surface. The one or more layers forming the outer
surface of the product are configured to provide a desired
aesthetic appearance to the exterior or interior surface of the
building wall and the base layer is configured to provide a thermal
insulative value and an acoustic insulative value to the
product.
[0008] Various objects and advantages of this invention will become
apparent to those skilled in the art from the following detailed
description of the various embodiments, when read in light of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a decorative, insulative
product.
[0010] FIG. 2 is a front view, in elevation, of a plurality of
decorative, insulative products of FIG. 1 combined such as to cover
a building wall.
[0011] FIG. 3 is a perspective view of a plurality of decorative,
insulative products of FIG. 1 combined such as to cover building
corner.
[0012] FIG. 4 is a side view, in elevation, of a mold for forming
the decorative, insulative product of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention will now be described with occasional
reference to the specific embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0014] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0015] Unless otherwise indicated, all numbers expressing
quantities of dimensions such as length, width, height, and so
forth as used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless otherwise indicated, the numerical properties
set forth in the specification and claims are approximations that
may vary depending on the desired properties sought to be obtained
in embodiments of the present invention. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
the invention are approximations, the numerical values set forth in
the specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0016] The description and figures disclose decorative, insulative
products configured for forming portions of interior or external
walls for a building and methods for the production of the
decorative, insulative products. The decorative, insulative
products can be in the form of panels, corner pieces, or
architectural trim pieces. As will be discussed below, the
decorative, insulative products are manufactured using a mold
filled with various layers of materials.
[0017] Referring now to the figures, a decorative, insulative
product is shown generally at 10. Generally, the decorative,
insulative product 10 (hereafter product 10) is configured to
provide both a decorative siding material and an insulative siding
material for application to external and internal surfaces of a
building. The product 10 includes layers of resin-based material
applied over a base of foam-based insulative material. The term
"decorative", as used herein, is defined to mean providing an
ornamental appearance. The term "insulative material", as used
herein, is defined to mean any material configured to provide a
thermal insulative value (R) or an acoustic insulative value. The
term "product", as used herein, is defined to mean any desired form
including panels, corner pieces and trim pieces. The term "layer",
as used herein, is defined to mean a quantity or thickness of
material. The term "resin-based", as used herein, is defined to
mean a material having a polymeric base.
[0018] As shown in FIG. 1, the product 10 has a front face 12, a
rear face 14, a top edge 16, a bottom edge 18, a first side edge 20
and a second side edge 22. As will be explained in more detail
below, the product 10 formed from a mold filled with various layers
of material. In the illustrated embodiment, the front face 12 has a
textured surface that simulates a plurality of natural stones. The
term "textured surface", as used herein, is defined to mean an
imitation of the tactile quality of a represented object. In other
embodiments, the front face 12 can have textured surfaces that
simulate other materials, such as the non-limiting example of
brick, natural wood, stucco or siding. However, it should be
appreciated that still in other embodiments, the front face 12 can
have a non-textured or smooth surface. The term "smooth" surface,
as used herein, is defined to mean a substantially continuous even
surface.
[0019] In the embodiment illustrated in FIG. 1, the top edge 16,
bottom edge 18 and opposing first and second side edges 20 and 22
have a smooth surface. Alternatively, in other embodiments, the top
edge 16, bottom edge 18 and opposing first and second side edges 20
and 22 can have textured surfaces that simulate other materials as
discussed above for the front face 12.
[0020] In the illustrated embodiment, the back face 14 of the
product 10 has a non-textured surface. Alternatively, the back face
14 can have any other texture, such as a scratch coat, conducive
for application to a structural surface.
[0021] Referring again to FIG. 1, the product 10 has a length LP
and a height HP. In the illustrated embodiment, the length LP of
the product 10 is in a range of from about 12.0 inches (30.5 cm) to
about 48.0 inches (121.9 cm) and the height HP of the product 10 is
in a range of from about 4.0 inches (10.2 cm) to about 16.0 inches
(40.6 cm). In other embodiments, the length LP of the product 10
can be less than about 12.0 inches (30.5 cm) or more than about
48.0 inches (121.9 cm) and the height HP of the product 10 can be
less than about 4.0 inches (10.2 cm) or more than about 16.0 inches
(40.6 cm). While the product 10 illustrated in FIG. 1 is shown as
having a generally rectangular shape, it should be appreciated that
in other embodiments, the product 10 can have other desired shapes,
including the non-limiting example of an irregular shape.
[0022] Referring again to FIG. 1, the product 10 includes an outer
layer 30, an optional intermediate layer 32 and a base layer
34.
[0023] The outer layer 30 is configured to provide a protective
surface and decorative surface to the product 10. In certain
instances, the product 10 can be applied to the exterior surfaces
of a building. Under these circumstances, the outer layer 30 of the
product 10 can be in contact with environmental conditions such as
rain, sleet, hail and snow. Accordingly, the outer layer 30 is
configured to substantially protect the product from damage from
the environmental conditions.
[0024] As discussed above, the outer layer 30 is configured to
provide a decorative surface to the product 10. Accordingly, the
surface of the outer layer 30 can have various coloring agents and
patterns.
[0025] In the illustrated embodiment, the material forming the
outer layer 30 is formed from an unsaturated polymeric-based
material, such as the non-limiting example of polyester resin or
epoxy resin. However, other desired materials can also be used,
sufficient to provide a protective surface and decorative surface
to the product 10. As will be discussed in more detail below, in
the illustrated embodiment, the outer layer 30 is formed by
spraying the unsaturated polymeric-based material into a mold.
However, in other embodiments, the outer layer 30 can be formed by
other desired methods, including the use of castable unsaturated
polymeric-based materials.
[0026] Optionally, the outer layer 30 can include reinforcing
materials (not shown). The reinforcing materials are configured to
provide the outer layer 30 with desired levels of hardness and
puncture resistance. In certain embodiments, the reinforcing
materials can be fibrous materials such as the non-limiting
examples of fiberglass or carbon fibers. In other embodiments, the
reinforcing materials can be other materials, such as for example
sand, quartz, ground up rubber tire and sawdust. In still other
embodiments, other suitable reinforcing materials can be used.
[0027] Optionally, the outer layer 30 can include various additives
or coatings configured to impart desired characteristics to the
product 10. As one non-limiting example, the outer layer 30 can
include a fire retardant material. Examples of fire retardant
material include aluminum hydroxide and boron. Other additives or
protective coatings can be added to tailor the outer layer 30 to
specialized conditions, such as extreme exposures of ultraviolet
light, solar radiation, and/or temperature. The protective coating
can also contain other additives such as algaecides or
fungicides.
[0028] The outer layer 30 has a thickness T1. The thickness T1 of
the outer layer 30 is configured to provide the outer layer 30 with
desired levels of strength and puncture resistance. In the
illustrated embodiment, the thickness T1 is in a range of from
about 0.02 inches (0.5 mm) to about 0.12 inches (3.0 mm). In other
embodiments, the thickness T1 of the outer layer can be less than
about 0.02 inches (0.5 mm) or more than about 0.12 inches (3.0
mm).
[0029] Referring again to embodiment illustrated in FIG. 1, the
product 10 includes the optional intermediate layer 32. The
optional intermediate layer 32 is configured to provide support to
the outer layer 30, such as to improve the rigidity and puncture
resistance of the outer layer 30. However, it should be appreciated
that in other embodiments, the size and shape of the product 10,
coupled with the configuration of the outer layer 30, may provide
the product 10 with sufficient rigidity and puncture resistance so
as to eliminate the need for the intermediate layer 32.
[0030] In the illustrated embodiment, the material forming the
intermediate layer 32 is an unsaturated polymeric-based material,
such as the non-limiting example of polyester resin, epoxy resin or
high density polyurethane foam. However, other desired materials
can also be used, sufficient to provide a support to the outer
layer 30. As will also be discussed in more detail below, in the
illustrated embodiment, the intermediate layer 32 is formed by
spraying the unsaturated polymeric-based material into the mold and
over the inner surface formed by the outer layer 30. However, in
other embodiments, the intermediate layer 32 can be formed by other
desired methods, including the use of castable unsaturated
polymeric-based materials.
[0031] Optionally, the intermediate layer 32 can include
reinforcing materials (not shown). The reinforcing materials are
configured to provide the intermediate layer 32 with desired levels
of strength and puncture resistance. In certain embodiments, the
reinforcing materials can be the same reinforcing materials used
for the outer layer 30, such as fiberglass or carbon fibers. In
other embodiments, the reinforcing materials can be other desired
materials.
[0032] The intermediate layer 32 has a thickness T2. The thickness
T2 of the intermediate layer 32 is configured to combine with the
thickness T1 of the outer layer 30 to provide the product 10 with
layers of resin-based material having a total desired thickness. In
the illustrated embodiment, the thickness T2 is in a range of from
about 0.12 inches (3.0 mm) to about 0.32 inches (8.0 mm). In other
embodiments, the thickness T2 of the intermediate layer 32 can be
less than about 0.12 inches (3.0 mm) or more than about 0.32 inches
(8.0 mm). Optionally, if needed, the thickness of the intermediate
layer 32 can be varied as desired such as to improve the rigidity
and puncture resistance of the outer layer 30 and to provide an
overall thickness of the layers of resin-based material.
[0033] In the illustrated embodiment, the combination of the
thicknesses T1 and T2 of the outer layer 30 and the intermediate
layer 32 is in a range of from about 0.14 inches (3.6 mm) to about
0.44 inches (11.2 mm). In other embodiments, the combination of the
thicknesses T1 and T2 of the outer layer 30 and the intermediate
layer 32 can be less than about 0.14 inches (3.6 mm) or more than
about 0.44 inches (11.2 mm).
[0034] Referring again to FIG. 1, the base layer 34 is configured
to provide a thermal insulative value (R) to the product 10 as well
as an acoustic insulative value to the product 10. The term
"insulative value", as used herein, is defined to mean the ability
of a material to substantially retard the flow of thermal energy.
Factors contributing to the thermal and acoustic insulative value
of the product 10 include the thicknesses of the base layer 34 and
the materials used to form the base layer 32.
[0035] The base layer 34 has a nominal or average thickness T3. In
the illustrated embodiment, the thickness T3 is in a range of from
about 0.59 inches (15.0 mm) to about 11.8 inches (300.0 mm). In
other embodiments, the thickness T3 of the base layer 34 can be
less than about 0.59 inches (15.0 mm) or more than about 11.8
inches (300.0 mm).
[0036] In the illustrated embodiment, the material forming the base
layer 34 is a polymeric-based foam material such as for example
polyurethane foam. In other embodiments, the material forming the
base layer 34 can be other materials or combinations of materials
including the non-limiting example of polyurethane foam combined
with expanded or extruded polystyrene foam. Accordingly, as one
non-limiting example, a base layer 34 having a thickness T3 of 0.79
inches (20 mm) and formed from a polymeric-based foam material
yields a thermal insulative value (R) of about 20. Other
combinations of the thickness of the base layer 34 and materials
forming the base layer 34 can provide other desired insulative
values (R).
[0037] In a similar manner, a base layer 34 having a thickness T3
of 0.79 inches (20 mm) and formed from a polymeric-based foam
material yields a noise reduction coefficient (NRC) in a range of
from about 0.2 to about 0.7. The NRC is a single-number index
determined in a lab test and used for rating how noise absorptive a
particular material is. This industry standard ranges from zero
(perfectly reflective) to 1 (perfectly absorptive). The NRC simply
averages the mid-frequency sound absorption coefficients (250, 500,
1000 and 2000 Hertz) rounded to the nearest 5%. Other combinations
of the thickness of the base layer 34 and materials forming the
base layer 34 can provide other desired acoustic insulative
values.
[0038] Optionally, the base layer 34 can include reinforcing
materials (not shown). The reinforcing materials are configured to
provide the base layer 34 with desired levels of rigidity and
puncture resistance. In certain embodiments, the reinforcing
materials can be fibrous materials such as the non-limiting
examples of fiberglass or carbon fibers. In other embodiments, the
reinforcing materials can be other materials, such as for example
sand, quartz, ground up rubber tire and sawdust. In still other
embodiments, other suitable reinforcing materials can be used.
[0039] Optionally, the base layer 34 can include various additives
or coatings configured to impart desired characteristics to the
product 10. As one non-limiting example, the base layer 34 can
include a fire retardant material as discussed above.
[0040] Referring now to FIG. 2, a plurality of products 10A-10G can
be combined to form a wall 50. In the embodiment as shown in FIG.
2, the products 10A-10G can optionally be shaped in a jig-saw
fashion such as to allow adjoining products 10A-10G to mesh
together in a more natural appearance and avoid the appearance of
rectangularly-shaped panels simply stacked together. In other
embodiments, the products 10A-10G can have other shapes, such as
the non-limiting examples of rectangular, square or irregular
shape, sufficient to allow adjoining products 10A-10G to mesh
together in a natural appearance.
[0041] In the illustrated embodiment, the adjoining side edges of
the products 10A-10G have substantially straight and smooth
surfaces, thereby allowing a tight fit between the adjoining
products 10A-10G. In other embodiments, the adjoining side edges of
the products 10A-10G can have other surfaces sufficient to allow a
tight fit between the adjoining products 10A-10G.
[0042] As shown in FIG. 2, an optional sealant 52 is positioned
between the adjoining side edges of the products 10A-10G. The
sealant 52 is configured to seal gaps formed between the adjoining
side edges of the products 10A-10G, thereby substantially
preventing the flow of acoustic energy, thermal energy and moisture
through the wall 50. In the illustrated embodiment, the sealant 52
is a polymeric material, such as for example polyurethane. However,
the sealant 52 can be other desired materials.
[0043] While the wall 50 illustrated in FIG. 2 is shown to have a
quantity of seven products 10A-10G and have a generally rectangular
shape, it should be appreciated that in other embodiments, a wall
can have any desired number of products 10 and can have any desired
shape, including an irregular shape.
[0044] Referring now to FIG. 3, a plurality of products 110A-110E
can be combined to form a corner 150. In the embodiment as shown in
FIG. 3, the products 110A-110E can optionally be shaped in a
jig-saw fashion such as to allow adjoining products 110A-110E to
mesh together in a more natural appearance and avoid the appearance
of rectangularly-shaped panels simply stacked together. In other
embodiments, the products 110A-110E can have other shapes, such as
the non-limiting examples of rectangular, square or irregular
shape, sufficient to allow adjoining products 110A-110E to mesh
together in a natural appearance.
[0045] In the illustrated embodiment, the adjoining side edges of
the products 110A-110E have substantially straight and smooth
surfaces, thereby allowing a tight fit between the adjoining
products 110A-110E. In other embodiments, the adjoining side edges
of the products 110A-110E can have other surfaces sufficient to
allow a tight fit between the adjoining products 110A-110E.
[0046] As shown in FIG. 3, an optional sealant 152 is positioned
between the adjoining side edges of the products 110A-110E. In the
illustrated embodiment, the sealant 152 is the same as, or similar
to, the sealant 52 illustrated in FIG. 2 and discussed above. In
other embodiments, the sealant 152 can be different from the
sealant 52 illustrated in FIG. 2 and discussed above.
[0047] While the corner 150 illustrated in FIG. 3 is shown to have
a quantity of five products 110A-110E, it should be appreciated
that in other embodiments, the corner 150 can have any desired
number of products. Also, while the corner 150 illustrated in FIG.
3 is shown such that the sides of the corner have a generally
right-angle orientation to each other, it should be appreciated
that in other embodiments, the sides of the corner can have any
desired orientation to each other.
[0048] Referring now to FIG. 4, a production mold is illustrated
generally at 60. The production mold 60 is configured to
manufacture the products 10. The production mold 60 includes a mold
frame 62 and structural material 64.
[0049] As illustrated in FIG. 4, the production mold 60 forms a
mold cavity 70 within the structural material 64. In the
illustrated embodiment, the mold cavity 70 is oriented such that
the outer layer 30 of the product 10 is arranged in a substantially
horizontal orientation. Alternatively, in other embodiments the
mold cavity 70 can be oriented such that the outer layer 30 of the
product 10 is arranged in a substantially vertical orientation.
[0050] While the production mold 60 illustrated in FIG. 4 shows a
lone mold cavity 70, it should be appreciated that the production
mold 60 can include any desired quantity of mold cavities 70.
[0051] The mold frame 62 is configured to support the structural
material 64. In the illustrated embodiment, the mold frame 62 is
made of a rigid material, such as for example metal. In other
embodiments, the mold frame 62 can be made of other rigid
materials, such as reinforced plastic, sufficient to hold the
structural material 64.
[0052] Referring again to FIG. 4, the structural material 64 is
positioned within the mold frame 62 and is configured to form the
mold cavity 70. The structural material 64 is configured to support
the load formed during the forming of the product 10. In certain
embodiments, the structural material 64 is a flexible material and
in other embodiments, the structural material 64 can be a rigid
material. Non-limiting examples of a flexible material forming the
structural material 64 include silicone rubber and polyurethane.
Non-limiting examples of rigid materials forming the structural
material 64 include epoxy-based resins, Teflon.RTM., polypropylene
and polyurethane-based resins. In still other embodiments, other
desired materials can be used to form the structural material 64,
sufficient to be a load supporting material capable of providing
substantially rigid structural support during the formation of the
product 10.
[0053] In other embodiments, the production mold 60 can be made
from a solid block of material. The production mold 60 material can
be any material suitable to form a mold 60 containing mold cavities
70. Non-limiting examples of suitable material include latex
rubber, elastomers such as polyurethane, and thermoplastics such as
polyvinyl chloride.
[0054] Having described the structure of the production mold 60,
the process for forming the product 10 will now be described.
Initially, the production mold 60 is positioned on a mold support
(not shown). The mold support is configured to retain the
production mold 60 is a rigid and fixed position during the mold
process. The mold support can have any desired structure.
[0055] Optionally, the mold support can be supported by mold
isolation mechanisms (not shown). The mold isolation mechanisms are
configured to isolate the production mold 60 as the production mold
60 is vibrated by an optional mold vibrator (not shown). The mold
isolation mechanisms can be any desired structure, mechanism or
device, or combination thereof, such as for example elastomeric
isolators or air bags, sufficient to isolate the production mold 60
as the production mold 60 is vibrated by the mold vibrator.
[0056] Optionally, the mold support can be configured for vertical
movement as may be required for positioning the production mold 60
relative to dosing apparatus (not shown). In certain embodiments,
the mold support can be connected to a hydraulic lift cylinder (not
shown), configured to facilitate the vertical movement of the
production mold 60. In other embodiments, the mold support can be
connected to other structure or mechanisms, such as for example
pneumatic or electric cylinders, or rack and pinion mechanisms,
sufficient to vertically raise and lower the mold support.
[0057] Referring again to FIG. 4, optionally, a mold vibrator (not
shown) can be connected to the mold support. The mold vibrator is
configured to vibrate the production mold 60. Vibration of the
production mold 60 can promote a flow of the materials forming the
layers 30, 32 and 34 of the product 10 into all portions of the
mold cavity 70. In certain embodiments, the mold vibrator can be a
pneumatic, high-amplitude piston-type vibrator providing a liner
force. One example of a pneumatic, piston-type vibrator is model
VTS 50/10, marketed by Powtek Corporation, headquartered in
Bensalem, Pa. In other embodiments, the mold vibrator can be other
suitable vibrators, such as for example electric or rotary
vibrators, sufficient to promote a flow of materials into all
portions of the mold cavity 70.
[0058] In operation, the production mold 60 is secured to the mold
support. Optionally, the mold cavity 70 can be colored or painted
with one or more layers of suitable stone-colored paints. The paint
can be applied with any desired manual or automatic mechanism or
device.
[0059] Next the mold support, including the production mold 60 is
positioned relative to one or more dosing apparatus (not shown).
The term "dosing" as used herein, is defined to mean the use of
defined quantities of material to manufacture the products 10.
Generally, the dosing apparatus is configured to allow a flow of
material to the mold cavity 70. The dosing apparatus can have any
desired structure, mechanism or device or combinations thereof. In
certain embodiments, a lone dosing apparatus can be configured to
sequentially apply the material for the outer layer 30 and the
intermediate layer 32. In other embodiments, separate dosing
apparatus can be used for application of the outer layer 30 and the
intermediate layer 32.
[0060] Optionally, the dosing apparatus can be connected to supply
hoppers (not shown). The supply hoppers are configured to supply
material for the layers 30 and 32 to the dosing apparatus. The
supply hoppers can be any desired structure, mechanism or device or
combination thereof.
[0061] Next, a desired quantity of material forming the outer layer
30 flows through the supply hopper and into the dosing apparatus.
As discussed earlier, in certain embodiments the material forming
the outer layer 30 can be sprayable, such as to be sprayed into the
mold cavity 70. In other embodiments, the material forming the
outer layer 30 can be deposited or cast into the mold cavity 70.
The quantity of material is sufficient when the formed outer layer
30 has a thickness T1 in the range as discussed above. Optionally,
the material can be urged to flow into all portions of the mold
cavity 70 by activation of the mold vibrator. Activation of the
mold vibrator can change the rheological properties of the material
and allow the material to flow more easily into all portions of the
mold cavity 70.
[0062] After the mold cavity 70 has received the desired quantity
of material forming the outer layer 30, the dosing apparatus and
the mold vibrator are deactivated and the material within the mold
cavity 70 is allowed to harden. Optionally, any desired apparatus
and any desired methods can be used to facilitate the hardening of
the material forming the outer layer 30.
[0063] Next, a desired quantity of material forming the
intermediate layer 32 flows through a supply hopper and into a
dosing apparatus. As discussed earlier, in certain embodiments the
material forming the intermediate layer 32 can be sprayable, such
as to be sprayed over the outer layer 30 in the mold cavity 70. In
other embodiments, the material forming the intermediate layer 32
can be deposited or cast over the outer layer 30 in the mold cavity
70. The quantity of material is sufficient when the formed
intermediate layer 32 has a thickness T2 in the range as discussed
above. Optionally, the material can be urged to flow into all
portions of the mold cavity 70 by activation of the mold vibrator,
as discussed above.
[0064] After the mold cavity 70 has received the desired quantity
of material forming the intermediate layer 32, the dosing apparatus
and the mold vibrator are deactivated and the material within the
mold cavity 70 is allowed to harden. Optionally, any desired
apparatus and any desired methods can be used to facilitate the
hardening of the material forming the intermediate layer 32, such
as the non-limiting example of a curing chamber.
[0065] Prior to the hardening of the intermediate layer 32, the
thicknesses T1 and T2 are determined using any desired method. If
the thicknesses T1 and T2 are not sufficient to provide the
thickness of the resin-based layers as discussed above, then
additional material is added to the intermediate layer 32 using the
apparatus and methods described above.
[0066] After the mold cavity 70 has received the desired quantity
of material forming the intermediate layer 32, the dosing apparatus
and the mold vibrator are deactivated and the material within the
mold cavity 70 is allowed to set to a gel condition. Optionally,
any desired apparatus and any desired methods can be used to
facilitate the setting of the material forming the intermediate
layer 32.
[0067] After the intermediate layer 32 has set to a gel condition,
the material forming the base layer 34 is deposited within the mold
cavity 70 by a foam dosing apparatus (not shown). A desired
quantity of foam material forming the base layer 34 flows through
the dosing apparatus. The quantity of foam material is sufficient
when the base layer 34 is formed having a thickness T3 in the range
as discussed above. The deposited material forming the base layer
34 contacts and bonds with the intermediate layer 32. Optionally,
the foam material can be urged to flow into all portions of the
mold cavity 70 by activation of the mold vibrator, as discussed
above.
[0068] Optionally, the top of the mold cavity 70 cavity can be
enclosed by a cap (not shown). The cap can be configured such as to
control the vertical expansion of the foam material forming the
base layer 34. The optional cap can be any desired structure,
mechanism or device sufficient to control the vertical expansion of
the foam material forming the base layer 34. However, it should be
understood that the cap is optional, and that the decorative,
insulative product 10 can be practiced without the cap.
[0069] Upon hardening of the base layer 34, the outer layer 30, and
intermediate layer 32, the material in the mold cavity 70 becomes
the product 10. After hardening, the product 10 is removed from the
mold cavity 70 in a suitable manner, including passing the
production mold 60 over rollers (not shown). Alternatively, any
other method of removing the product 10 from the production mold
60, such as introducing a pressurized fluid such as air between the
outer layer 30 and the structural material 64, or vacuum absorption
can be used.
[0070] Referring again to FIG. 4, optionally, a removal or release
agent can be applied to the mold cavity 70 prior to the deposition
of the materials. The removal or release agent is configured to
facilitate removal of the product 10 from the mold cavity 70. The
removal or release agent can be any desired material or combination
of materials.
[0071] Optionally, after the product 10 has been removed from the
mold 60, the product 10 can be further thermally cured using any
desired curing apparatus or method, such as for example a curing
oven (not shown). In certain embodiments, the optional curing can
also be used to substantially reduce or eliminate any residual
odors.
[0072] While the production mold 60 illustrated in FIG. 4 has been
described above as one method of forming the product 10, it should
be appreciated that other methods of manufacturing the product 10
can be used. As one non-limiting example of another method of
forming the product 10, the following production steps can be used.
First, the base layer 34 can be formed by introducing foam material
forming the base layer 34 into a mold (not shown) having a mold
cavity. The mold cavity can have a textured surface that simulates
a plurality of natural stones. In other embodiments, the mold
cavity can have textured surfaces that simulate other materials,
such as the non-limiting example of brick, natural wood, stucco or
siding. However, it should be appreciated that still in other
embodiments, the mold cavity can have a non-textured or smooth
surface. The term "smooth" surface, as used herein, is defined to
mean a substantially continuous even surface.
[0073] The foam material can be the same as the foam material
discussed above, however other foam materials can be used.
Optionally, the foam material can be urged to flow into all
portions of the mold cavity by activation of the mold vibrator, as
discussed above, or by other desired methods including pressure
formed by apparatus in the form of a press.
[0074] Upon hardening, the foam material forming the base layer
having the optional textured surface, is removed from the mold
cavity. An outer layer and optionally an intermediate layer can be
applied to the base layer. The outer layer and optional
intermediate layer can be applied to the base layer in any desired
manner, including spraying, casting or depositing, using any
desired structures, mechanisms or devices. Upon application, the
outer layer and optional intermediate layer assume the optional
textured surface of the base layer. Optionally, the outer layer can
be aesthetically finished as desired.
[0075] The principle of the decorative, insulative product and
methods for the production of the decorative, insulative product
have been described in certain embodiments. However, it should be
noted that the decorative, insulative product and methods for the
production of the decorative, insulative product may be practiced
otherwise than as specifically illustrated and described without
departing from its scope.
* * * * *