U.S. patent number 3,856,611 [Application Number 05/323,141] was granted by the patent office on 1974-12-24 for decorative panel with finished edges.
This patent grant is currently assigned to Sackner Products, Inc.. Invention is credited to Jerry M. Markley.
United States Patent |
3,856,611 |
Markley |
December 24, 1974 |
**Please see images for:
( Certificate of Correction ) ** |
DECORATIVE PANEL WITH FINISHED EDGES
Abstract
A decorative panel for vehicle interiors and the like having
covered, finished edges and corners and a method for making same. A
flexible cover sheet is adhered to foldable edges of a relatively
stiff backing layer with a dielectrically sealable padding layer
interposed therebetween. The foldable edges are folded against and
secured to the back of the panel thereby stretching the cover
around the resulting finished panel edges. The folded edges also
overlap and help secure the previously folded corners of the cover
sheet which are also adhered to the panel back. A decorative
pattern which may be dielectrically sealed in the front of the
panel simultaneously with the sealing of the cover to the foldable
edges.
Inventors: |
Markley; Jerry M. (Wyoming,
MI) |
Assignee: |
Sackner Products, Inc. (Grand
Rapids, MI)
|
Family
ID: |
23257886 |
Appl.
No.: |
05/323,141 |
Filed: |
January 12, 1973 |
Current U.S.
Class: |
428/76; 5/402;
52/511; 156/216; 156/219; 428/116; 428/126; 428/161; 428/319.7;
297/219.1 |
Current CPC
Class: |
B32B
27/30 (20130101); B60R 13/02 (20130101); B32B
5/18 (20130101); B32B 27/12 (20130101); B44C
5/04 (20130101); B32B 29/007 (20130101); B32B
3/04 (20130101); B32B 7/12 (20130101); B32B
17/02 (20130101); B32B 29/08 (20130101); B44C
1/105 (20130101); B32B 27/065 (20130101); B32B
2327/06 (20130101); Y10T 156/1039 (20150115); Y10T
428/249992 (20150401); B32B 2331/04 (20130101); Y10T
428/24231 (20150115); Y10T 156/1034 (20150115); B32B
2605/003 (20130101); Y10T 428/239 (20150115); Y10T
428/24521 (20150115); B32B 2451/00 (20130101); Y10T
428/24149 (20150115) |
Current International
Class: |
B60R
13/02 (20060101); B32b 001/04 () |
Field of
Search: |
;5/353.1,353.2
;52/511,513,631 ;156/211,212,213,216,219,257
;161/41,43,44,99,102,68,104,105,109,112,108,149,119,160,DIG.3,45,86,118,147
;297/218,219 ;229/40,87R |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Ansher; Harold
Assistant Examiner: Epstein; Henry F.
Attorney, Agent or Firm: Price, Heneveld, Huizing &
Cooper
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows.
1. A decorative panel comprising the combination of a stiff backing
layer, a pad having dielectrically sealable means incorporated
therein, and a dielectrically embossable cover of flexible
material; said backing having a periphery with foldable margins
foldable along predetermined rectilinear lines; said pad and cover
being dielectrically embossed and sealed to said backing in an area
thereof along said rectilinear lines, said area of said backing
being located outwardly of said rectilinear lines; said margins
being folded against the back of the backing and adhered thereto
whereby uniformly finished panel edges are formed with said cover
extending therearound.
2. The decorative panel of claim 1 wherein said backing layer is
corrugated cardboard, said rectilinear lines comprising fold
guidelines scored only partially through said cardboard.
3. The decorative panel of claim 1 wherein said flexible covering
material is vinyl plastic.
4. The decorative panel of claim 1 wherein said cover is sealed to
said area of said backing with a dielectrically activatable
adhesive.
5. The decorative panel of claim 1 wherein said panel includes at
least one folded corner, said corner comprising a portion of said
cover folded over a truncated corner of said backing layer and
adhered to the back thereof; said rectilinear lines extending from
points along the edge of said truncated corner; said foldable
margins overlapping said folded and adhered corner on said back of
said backing layer whereby said folded corner is additionally
secured against pulling loose.
6. A decorative panel comprising in combination a backing support
and a flexible covering layer; said backing including front and
back surfaces; said covering including at least one extending
corner and being secured to said backing support on said front
surface along the periphery thereof; said backing support including
fold guidelines interior of said periphery separating said backing
support into foldable margins and a central support area; said
backing support further including at least one truncated corner
with an edge; said extending corner being folded over said corner
edge and secured to the back of said backing; said foldable margins
being folded against said back of said backing and secured thereto
in overlapping engagement with said extending corner whereby said
cover is wrapped around the periphery of said panel forming
finished, covered edges thereon and said extending corner is doubly
retained and prevented from loosening.
7. The decorative panel of claim 6 wherein said fold guidelines are
lines scored partially through said front surface of said backing
support.
8. The decorative panel of claim 6 wherein said covering is secured
to the periphery of said backing support via a dielectrically
activatable adhesive.
9. The decorative panel of claim 6 wherein said fold guidelines
extend between specified points on a plurality of said corner
edges; said points spaced apart a predetermined distance along said
corner edges; said corner edges being rectilinear.
10. The decorative panel of claim 6 wherein the outside dimensions
of said covering are less than the outside dimensions of said
backing support and greater than the outline formed by said fold
guidelines.
11. A decorative panel comprising in combination a backing support
and a flexible covering layer; said backing including front and
back surfaces; said covering including at least one extending
corner and being secured to said backing support on said front
surface along the periphery thereof; said backing support including
fold guidelines interior of said periphery separating said backing
support into foldable margins and a central support area; said
backing support further including at least one truncated corner
with an edge; said extending corner being folded over said corner
edge and secured to the back of said backing; said foldable margins
being folded against said back of said backing and secured thereto
in overlapping engagement with said extending corner whereby said
cover is wrapped around the periphery of said panel forming
finished, covered edges thereon and said extending corner is doubly
retained and prevented from loosening; said panel further including
a layer of padding between said backing support and said flexible
covering layer; said padding filling and rounding out said finished
edges of said panel.
12. The decorative panel of claim 11 wherein said padding layer
includes dielectrically sealable means; said padding and covering
being dielectrically embossed in a preselected pattern.
13. A decorative panel comprising in combination a backing support
and a flexible covering layer; said backing including front and
back surfaces; said covering including at least one extending
corner and being secured to said backing support on said front
surface along the periphery thereof; said backing support including
fold guidelines interior of said periphery separating said backing
support into foldable margins and a central support area; said
backing support further including at least one truncated corner
with an edge; said extending corner being folded over said corner
edge and secured to the back of said backing; said foldable margins
being folded against said back of said backing and secured thereto
in overlapping engagement with said extending corner whereby said
cover is wrapped around the periphery of said panel forming
finished, covered edges thereon and said extending corner is doubly
retained and prevented from loosening; the outside dimensions of
said covering being less than the outside dimensions of said
backing support and greater than the outline formed by said fold
guidelines; said panel further including a padding layer interposed
between said backing support and cover; said padding layer having
outside dimensions equivalent to the outline formed by said fold
guidelines.
Description
This invention relates to decorative panels for the interiors of
automobiles, trucks, mobile homes, and the like, and more
particularly, to decorative panels including a covering of flexible
materials wherein the panel edges and corners are covered and
finished by securing the flexible material to the back of the panel
in a unique manner.
BACKGROUND OF THE INVENTION
Decorative panels, including those having a covering of vinyl
plastic and other flexible materials, are widely known. Typically,
such decorative panels have included a relatively stiff backing
board over which the vinyl or other covering is manually wrapped
and secured to the back thereof. Such prior known decorative panels
are often difficult and time consuming to manufacture due to the
hand or manual operations required in the process. Thus, the vinyl
or other covering sheet must be exactly mitered or cut, especially
at its corners, prior to the installation on the backing board.
Then the covering must be precisely positioned on the backing after
which the protruding edges of the covering are laboriously hand
wrapped over the corners and edges of the backing and secured to
the back surface thereof. This process has often resulted in the
prior decorative panels having poorly finished corners and wavy,
uneven edges due in part to both the elasticity of the vinyl
covering and the fact that the adhesive securing the covering edges
to the back of the backing board is often not carefully applied.
Consequently, the prior methods often produced "open" corners
wherein the vinyl or other covering pulled loose from the back of
the backing board and puckered open thereby exposing the raw edges
of the loosened covering. The "open" corner result was often
compounded by the fact that the covering material was not exactly
cut and positioned on the backing board. Moreover, the prior panels
required the use of relatively expensive, extremely high strength
adhesives, such as "hot melt" polyethylene base adhesives, at
certain joints since it was necessary for those adhesives to
directly withstand the tensile forces present in the covering
materials wrapped around the panel edges.
Therefore, the prior decorative panels produced via the prior known
methods for finishing corners and edges thereon generally resulted
in decorative panels which were undesirable from one or more of the
above standpoints.
SUMMARY OF THE INVENTION
Accordingly, it is an object and purpose of the present invention
to provide a decorative panel having uniformly finished corners and
edges wherein the edges of the covering material are adequately and
securely fastened to the back of the panel in a quick and
convenient manner. The decorative panel embodying the present
invention provides significantly improved finished edges and
corners since the edges and corners are securely adhered to the
panel backing in a manner that prevents the edges and corners from
puckering, loosening or otherwise "opening" to expose the raw edges
of the flexible covering.
Further, it is another purpose to provide a unique method for
fastening the edges of the flexible covering to the back of the
panel such that the edges and corners of the flexible covering are
securely retained thereon without objectionable bulkiness,
puckering or uneveness.
In view of these objects and purposes, the invention provides a
decorative panel with finished edges and corners comprising in
combination a relatively stiff backing support layer, a layer of
padding and a covering sheet of flexible material. In the preferred
embodiment, the covering sheet extends over the truncated corners
of the stiff backing support layer with a dielectrically sealable
padding layer being interposed therebetween. The extending portions
of the covering layer are folded over the truncated corners and are
secured to the back surface. Further, the edges of the covering
layer are secured via suitable adhesives to the front surface of
the backing layer just interior of the peripheral edge thereof. In
one aspect of the invention, these covering layer edges may be
dielectrically sealed along the edges of the backing layer
simultaneously with the dielectric embossment of a selected
decorative pattern in the covering sheet and dielectrically
sealable padding layer.
Following the sealing of the covering layer edges to the backing
layer and the folding of the extending portions of the covering
layer over the truncated corners, the periphery of the backing
support is folded 180.degree. against the back thereof along
previously scored, or otherwise formed, fold guidelines outlining
the periphery of the padding layer. The folding of these peripheral
edges stretches the covering layer around the edge defined by the
fold guidelines thereby forming a finished edge which is rounded
and filled out by the padding layer. The folded periphery is
thereafter secured to the back of the backing support to complete
the assembly.
When assembled and completed, the folded edges of the backing layer
also overlap the previously folded and secured extending corner
portions of the cover sheet at the corners of the decorative panel
thereby forming a smoothly folded, finished corner which is doubly
secured to the panel back. This double retention comprises both the
primary securing of the cover sheet to the back of the backing
layer via suitable adhesive in addition to the overlapping
engagement of the folded peripheries of the backing layer.
Consequently, the resulting decorative panel includes finished
corners which include little or no pucker, are securely adhered to
the back surface of the backing layer and are prevented from
loosening or "opening" because of the overlapping nature of the
bendable, peripheral flaps. Further, the covered edges of the
decorative panel are uniform and include little or no uneveness
since the covering material is folded and stretched over the fold
lines defined by the scoring on the front surface of the backing
layer and adhered securely to the back surface of the backing layer
via the folded flaps.
Moreover, the padding layer provides the panel with a luxuriant,
resilient depth adding to the aesthetic appeal of the finished
panel. Additionally, the padding layer fills out and provides
roundness for the folded edges and corners of the resultant panel.
Further, since it is preferable that the backing layer be formed
from corrugated or other cardboard, an adhesive suitable for
bonding paper to paper is used in securing the peripheral flaps to
the back surface of the backing layer. Such an adhesive is
generally less expensive than other previously used adhesives.
Additionally, another advantage of the present invention is that it
provides a decorative panel with covered and finished edges and
corners while obviating the need to exactly miter or cut the edges
and corners of the covering material prior to installation on the
panel. Thus, the covering layer need not be precisely positioned on
the backing layer, but need only be positioned such that portions
thereof extend beyond the diagonal edges of the truncated corners
provided on the backing layer. While other portions extend over the
fold guidelines for adherence to the foldable flaps. If only these
two dimensional requirements are met, the present method allows the
production of uniformly covered edges and corners without attention
to dimensional detail.
These and other objects, advantages, purposes and features of the
invention will become apparent from a study of the following
description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a decorative panel of the present
invention shown in a typical installation on the interior of an
automobile door;
FIG. 2 is a perspective view of the decorative panel of FIG. 1
showing the rounded, uniform corners and edges obtained via the
present invention;
FIG. 3 is a broken, back, plan view of the decorative panel of
FIGS. 1 and 2 showing the configuration of the backing layer and
covering sheet in phantom prior to folding as well as the finished
corners and edges;
FIG. 4 is a broken, cross-sectional view of the decorative panel
taken along plane IV--IV of FIG. 3;
FIG. 5 is a perspective view of the backing support layer included
in the present invention with the bendable, peripheral flaps shown
partially folded in phantom;
FIG. 6 is an exploded, perspective view of the several parts of the
decorative panel of the present invention shown prior to
assembly;
FIG. 7 is a perspective view of a partially assembled decorative
panel after the adhering of the flexible covering layer to the
backing layer and prior to the folding of the extending portions of
the covering layer and the folding of the bendable peripheral
flaps;
FIG. 8 is an enlarged, fragmentary, perspective view of the back
surface of one corner of a partially assembled decorative panel;
and
FIG. 9 is an enlarged, fragmentary, perspective view of one corner
of a completed decorative panel showing an extended portion of the
covering layer folded and secured beneath the bendable, peripheral
flaps on the back surface of the backing layer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in greater detail, FIG. 1 illustrates
a decorative panel 10 embodying the present invention shown secured
in a typical installation as an interior panel on the interior of
an automobile door 11. Generally, such panels may also be used in
various decorative installations and application such as in mobile
homes, motor homes, trucks, buses, yachts, and indeed all
installations where a fabric or vinylcovered panel is desired for
decorative purposes. As shown in FIG. 2, the panel 10 includes
finished corners 12 and edges 14. Both the corners 12 and edges 14
are uniformly covered with a flexible covering sheet 40 as will be
described more fully below. The panel may include various
decorative embossed patterns 55 for enhancing the appearance
thereof.
As is best shown in FIGS. 4 and 5-7, each decorative panel 10, in
the preferred embodiment, comprises three elements including a
backing support layer 20, a covering sheet or layer of flexible
material, and a padding layer 50 interposed between the backing
layer 20 and covering layer 40. Preferably, the backing layer 20 is
a sheet of corrugated cardboard as shown in FIG. 4. Other
relatively stiff solid cardboard or fiberboard sheets and the like
may also be used. The covering sheet of flexible material 40
preferably comprises a dielectrically sealable vinyl plastic, vinyl
impregnated cloth or another similarly durable, flexible material.
The padding layer 50 may be any type of fibrous or foamed padding
layer but preferably comprises a fusible, polymeric, foam fibrous
pad of the type described in U.S. Pat. No. 3,354,020, issued to
Richard S. Copeland, and assigned to the same assignee as the
present invention, the disclosure of which is incorporated by
reference herein. Although various other types of padding layers
are acceptable, the foam fibrous pad described in the Copeland
patent provides desirable dielectric and resilient qualities adding
to the overall aesthetic and structural advantages of the present
decorative panel. Although the padding layer is included in the
preferred embodiment, decorative panels using the present novel
edge and corner forming concepts may be made without intermediate
padding layers.
The basic concept of the present invention resides in th provision
of finished edges and corners for the decorative panel 10 via a
unique method of securing the covering sheet or layer 40 over the
padding layer 50 and around the peripheral edges of the panel 10 to
the backing support layer 20. Foldable edges on the backing
support, with the covering sheet edges attached thereto, are folded
back and secured against the back surface of the decorative panel
10. The folded backing support edges clamp the previously folded,
extending corner portions of the covering sheet 40 against the back
surface of the backing support layer. In addition, the method of
fastening the covering sheet edges to the backing support is secure
since those edges are first adhered to the foldable peripheral
flaps of the backing layer ad thereafter portions of those edges
are clamped between the folded flaps and the backing support. This
provides a double assurance against the release of the covering
sheet edges. Thus, a panel is provided having finished corners and
uniformly straight, even, finished edges both of which are securely
retained and prevented from loosening. Moreover, the finished edges
and corners are manufactured via a method which is quicker, more
convenient and much easier to perform than the previously known
covering methods.
In reference to FIGS. 3, 4, and 5, the backing support layer 20
includes a front, generally planar surface 22 as well as a back,
generally planar surface 24. These surfaces are parallel and
correspond to the outer surfaces of the corrugated cardboard
mentioned above. In the preferred embodiment, these surfaces will
be spaced apart by a corrugated inner member 26 (FIG. 4). However,
when other types of cardboard are utilized, the inner area of the
backing layer 20 between surfaces 22 and 24 may be solid,
honeycombed, etc. The backing layer 20 includes peripheral edges 28
and truncated corners 30 forming diagonal edges 32 extending
between the peripheral edges 28. The truncated corners are formed
merely by removing the apexes of any corners. Preferably, the
diagonal edges 32 formed by the truncated corners 30 are formed
such that the angles between the diagonal edge and each of the
peripheral edges which it joins are equal. These angles are
represented by A and B in FIG. 3.
The edges of the finished panel 10 are formed via fold guidelines
34 which are scored or cut in the front surface 22 of backing layer
20. Scored lines 34 thereby divide the backing layer 20 into
bendable, peripheral flaps 36 and a central backing support area
38. Preferably, the lines 34 are scored or cut only partially
through the thickness of the backing layer 20. Thus, in the
preferred embodiment using corrugated cardboard, guidelines 34 are
cut or scored through only the outer surface 22 and the corrugated
inner member 26. The remaining outer surface 24 is thereby left
intact and serves as a hinge for folding flaps 36. Consequently,
the bendable, peripheral flaps 36 may be bent or folded backwards
through 180.degree. from their original positions against the back
surface 24 of backing layer 20.
The scored lines 34 extend between points 33 (FIGS. 3 and 8) on the
diagonal edges 32 along and adjacent to the peripheral edges 28. In
the preferred embodiment, points 33 are spaced slightly apart a
small distance represented by D in FIGS. 3, 8, and 9 thereby
forming an intermediate area 35 on edge 32. Points 33 are located
along the diagonal edges approximately midway between the two
peripheral edges joined by each of those diagonal edges. The slight
spacing D between points 33 provides a slight spacing between the
folded flaps 36 when secured to back surface 24 as shown in FIG. 9.
The central location of points 33 on diagonal edges 32 provides
approximately equivalent widths for all of the flaps 36 around the
entire periphery of the central backing support area 38.
Referring now to FIGS. 3, 6, and 7, the covering sheet or layer 40
comprises a piece of flexible material of the type described above
having a geometrical shape corresponding to that of the backing
layer 20 but having slightly smaller, overall dimensions. The sheet
cover 40 has sufficient dielectrically sealable qualities such that
it may be dielectrically sealed to said padding layer 50 in
preselected patterns. In the preferred embodiment, the backing
support layer 20, as well as the covering layer 40 and padding
layer 50, are rectangular. However, it will be understood that the
decorative panels 10 and elements thereof may be made in any
geometrical shape. Covering sheet 40 includes extending portions or
corners 42 which extend beyond the diagonal edges 32 of truncated
corners 30. Portions 42 need not be triangular in shape as they are
shown in FIG. 3, but may have any sufficient material shape as long
as sufficient provided to fold over edge 32 and cover the area 35
of edge 32 between points 33. Generally, the dimensions of the
covering sheet 40 are sufficient to allow the edges 44 of the
covering sheet to partially cover the bendable flaps 36 as shown in
FIG. 7. Thus, the covering sheet 40 extends past the scored lines
34, over the peripheral flaps 36 and is secured thereto with a
suitable adhesive. As will be explained more fully below, this
adhesive is of the type which is suitable for securing vinyl
plastic, vinyl impregnated cloth, or other fabrics or synthetics to
paper or cardboard.
As shown in FIG. 6, the intermediate padding layer 50, which is
included in the preferred embodiment, has a geometric shape
corresponding to the outline of the finished panel, i.e., the
outline formed by the scored lines 34. Therefore, the padding layer
will extend within the entirety of the complete, finished
decorative panel 10 and provides sufficient padding to fill and
round out the finished edges and corners of the panel 10.
The adhesive used to adhere the peripheral edges 44 of cover sheet
40 to peripheral flaps 36 is preferably any dielectrically
activatable adhesive such as those in the group including polyvinyl
acetate, polyvinyl chloride or any of several acrylic adhesives.
The adhesive used to secure extending corners 42 to back surface 24
may also be such a dielectrically actuatable adhesive but is
preferably a water base, contact cement. The adhesive used to
adhere the peripheral flaps 36 to back surface 24 is preferably
also water base, contact cement. Of course, if the dielectrically
activatable adhesives are not used, the same adhesive, such as
water base, contact cement, may be used for all joints in the
panel. Thus, the water base, contact cement is suitable for
adhering both vinyl or fabric to paper as well as paper to paper.
This type of cement or adhesive is generally less expensive than
other types of adhesives used in prior methods of securing covering
sheets to backing supports such as "hot melt" polyethylene base
adhesives.
DESCRIPTION OF THE METHOD
Referring now to FIGS. 5 through 9, the process for making the
decorative panels 10 in accordance with the present novel inventive
concepts will be described in greater detail. As shown in FIG. 5, a
backing support layer 20 is provided with any corners thereon being
removed along a diagonal line between the two peripheral edges
forming the corner. Thus, truncated corners 30 are formed having
diagonal edges 32. As described above, the diagonal edges in the
preferred embodiment form the same angle with each of the edges 28
(represented by equivalent angles A & B in FIG. 3). In the
rectangular panels shown herein, these angles will, of course, be
45.degree..
After cutting the backing layer 20 to the desired shape, fold
guidelines 34 are scored on the front surface 22 of the backing
layer 20. In the preferred embodiment, lines 34 are scored only
partially through the corrugated cardboard backing layer 20 and are
rectilinear lines extending between the points 33 located
approximately midway along the diagonal edges 32 of the several
truncated corners 30. The scored lines 34 form the peripheral flaps
36 and central backing support area 38, the peripheral flaps 36
being allowed to bend through 180.degree. via the hinge areas of
back surface 24. Thus flaps 36 may be bent to lie flat against the
back surface 24 of the backing layer 20. The outline of the scored
lines 34 will, of course, correspond to the outline of the finished
decorative panel 10.
Following the scoring of the guidelines 34 on thefront surface of
the backing layer 20, an adhesive suitable for securing the
flexible covering sheet 40 to the backing layer 20 is applied to
portions of the front surface 22 including the front surfaces of
the peripheral flaps 36. In the preferred embodiment, as described
above, this adhesive will be a dielectrically activatable adhesive
such as polyvinyl acetate, polyvinyl chloride, or an acrylic
adhesive. Furthermore, in the preferred embodiment, this
dielectrically activatable adhesive (not shown) will be applied
over the entirety of the front surface 22 of the central backing
support area 38 such that the covering layer 40 and padded layer 50
may be dielectrically embossed with a decorative pattern by fusing
the cover 40 and pad 50 to the front surface 22 in certain areas
simultaneously with the sealing of the covering sheet edges 44 to
the peripheral flaps 36. It is possible to commercially obtain
backing support materials such as cardboard or fiberboard already
having coatings or such dielectrically activatable adhesives
applied thereto. Absent such precoated backing layers, however, the
adhesive may be applied as needed.
Following the application of a suitable adhesive to the front
surface 22, or portions thereof, the padding layer 50 is laid
within the outlines of the scored lines 34 atop the front surface
22. Next, the covering sheet or layer 40 is laid over the top of
the padding layer 50 with its edges 44 resting along the peripheral
flaps 36 and its extending corners 42 protruding beyond the
diagonal edges 32 of truncated corner 30. In this step exact
positioning is not crucial, the only requirement being that corners
42 protrude over edges 32. Following the above assembly, the edges
44 of the covering layer 40 are adhered (via dielectrically sealing
in the preferred embodiment) to the peripheral flaps 36. This step
is preferably done simultaneously with embossing a decorative
pattern 55 in the central areas of the decorative panel 10 as shown
in FIGS. 1 and 2. In this connection, it will be understood that
the padding layer 50 will be composed of a foam-fibrous pad of the
type described in Copeland U.S. Pat. No. 3,354,020. This is a
non-woven pad which is particularly suited for dielectric
embossing.
Subsequent to the sealing of edges 44 to peripheral flaps 36, the
extending corners or portions 42 of covering layer 40 are tightly
folded around diagonal edges 32 and adhered via a suitable adhesive
to the back surface 24 of backing layer 20 as shown in FIG. 8. As
described above, the adhesive used for this operation may be a
dielectrically activatable adhesive such that the extending corner
42 is dielectrically sealed to the back surface 24 but is
preferably a water base, contact cement.
Thereafter, each of the bendable, peripheral flaps 36 is folded
through 180.degree. via the hinge areas of back surface 24 such
that the extending corners 42 are folded and secured between the
flaps 36 and the back surface 24. The flaps 36 are then adhered to
the back surface 24 via a suitable adhesive which is preferably a
water base, contact cement as described above.
As shown in FIG. 9, the respective portions of diagonal edge 32 are
spaced slightly apart by a distance "D" and extend parallel to one
another inwardly from the finished corner 12 overtop the folded
extending corner 42 which lies between the flaps 36 and back
surface 24. The result is a neatly and smoothly folded, finished
and covered corner 12 which has no puckering and minimal bulkiness
and which has little tendency to pull loose or "open" and,
therefore, expose the raw edges of the covering material 40 as was
experienced with the prior construction methods of manufacturing
decorative panels. It will be understood that the overlapping
nature of the peripheral flaps 36 over the folded extending corner
42 is a major reason for preventing the "opening" of the finished
corners. This overlapping feature is also a major factor in
providing the extremely strong and secure joint between the cover
sheet edges 44 and the backing layer 20. As mentioned above, edges
44 are doubly secured against loosening. They are first adhered to
flaps 36. Subsequently, corner portions of the edges are clamped
and engaged between the folded flaps 36 and back surface 24 of
backing support 20. Thus, even if the bond between the edges and
flaps should loosen, the edges will remain tightly held between
flaps 36 and back surface 24 in the area finished corners 12.
Consequently, this double retention or fastening effectively
counteracts any tensile forces in the covering sheet which is
stretched around the panel edges, and prevents those forces from
loosening the finished corners and edges.
Additionally, it will be understood that the finished edges 14 of
the panel 10 will be uniformly even since they follow the length of
the scored lines 34 forming the fold guidelines as shown in FIGS. 2
through 4 and 9. The covering material 40 is vinyl in the preferred
embodiment and, thus, includes a certain degree of integral
resiliency such that the vinyl is stretched around the corner 14.
This results in an aesthetically pleasing uniform edge since the
vinyl is filled and rounded out by the padding layer 50 between the
backing layer and covering.
Further, it will be understood that the process of assembling the
decorative panel 10 in the above manner is significantly faster and
more convenient since the various components need not be precisely
positioned with respect to one another. Rather, the covering layer
need only be positioned with its edges 44 adjacent the peripheral
flaps 36 and its extending corners 42 extending beyond the diagonal
edges 32. Thus, it may be skewed slightly in the assembly process
without producing adverse effects in the finished decorative panel.
Moreover, the corners and edges of the covering sheet 40 need not
be exactly mitered or cut prior to installation thereby allowing
the flexible covering material to be machine cut which reduces the
overall expense and costs involved as well as the time required for
the manufacturing process.
Consequently, each panel produced in accordance with the present
inventive concepts will include finished corners and edges which
are similar to those produced on all other panels made using the
same method. Uniformity and high quality production standards are
therefore assured. In addition, the overall cost of each panel is
effectively reduced because of lesser production time required for
each panel made with the present method as well as the relatively
less expensive materials required, such as the water base, contact
cement used in several of the joints of the panel.
It will be understood that the descriptive terms "top," "bottom,"
"front," and "back," are used merely for descriptive purposes and
are not intended to limit the scope of the invention.
While one form of the invention has been shown and described, other
forms will now be apparent to those skilled in the art. Therefore,
it will be understood that the embodiment shown in the drawings and
described above is merely for illustrative purposes, and is not
intended to limit the scope of the invention which is defined by
the claims as follows.
* * * * *