Natural effect panel and method of fabricating the same

Abstract

A method comprising layering a base layer; depositing a layer of wood particles on the base layer; dispersing the wood particles evenly within a frame; layering a paper sheet; compressing the wood particles with the paper sheets to obtain an enwrapped composite board; layering a kraft paper, a decorative paper and an overlay paper by sequence on the composite board, wherein the kraft paper, the decorative paper and the overlay paper are resin impregnated; and compressing the layered kraft paper, decorative paper and overlay paper to the top and side of the composite board with a carved mould under heat and pressure; thereby forming the natural effect panel that having an irregular surface from top to the side including edge of the panel.

Claims

1. A method of fabricating a natural effect panel (100), the method comprising the steps of: layering a resin impregnated paper sheet (101) as a base layer; depositing a layer of wood particles (102) on the base layer; dispersing the wood particles (102) evenly within a frame; layering a paper sheet (103) on the wood particles (102); compressing the wood particles (102) with the paper sheets (101, 103) to obtain an enwrapped composite board; layering a kraft paper (104), a decorative paper (105) and an overlay paper (106) by sequence on the enwrapped composite board, wherein the kraft paper (104), the decorative paper (105) and the overlay paper (106) are resin impregnated; and compressing the layered kraft paper (104), decorative paper (105) and overlay paper (106) onto a top surface of the enwrapped composite board and lateral surfaces of the enwrapped composite board with a carved mould under heat and pressure, wherein the carved mould comprises protrusions configured to form the natural effect panel (100) having an irregular surface, the irregular surface covering the top surface of the enwrapped composite board and extending from an upper edge of the enwrapped composite board to the lateral surfaces of the enwrapped composite board.

2. The method as claimed in claim 1, wherein said irregular surface comprises a plurality of indentations uniformly formed thereon.

3. The method as claimed in claim 1, wherein said kraft paper (104), decorative paper (105) and overlay paper (106) are layered to form a high pressure laminate.

4. The method as claimed in claim 1, wherein the resin impregnated paper sheet (101) is a kraft paper impregnated with resin.

5. The method as claimed in claim 1, wherein said wood particles (102) comprises saw dust particles.

6. The method as claimed in claim 1, wherein said paper sheet (103) is a paper having pores and without resin or coating.

7. The method as claimed in claim 1, wherein an equal pressure is applied towards the top surface of the enwrapped composite board and the lateral surfaces of the enwrapped composite board when compressing the layered kraft paper, the decorative paper and the overlay paper to obtain a uniform carving pattern.

8. The method as claimed in claim 1, wherein the step of compressing the layered kraft paper, the decorative paper and the overlay paper is performed at temperature of 180° C.

9. The method as claimed in claim 3, wherein the step of compressing leads to formation of the high pressure laminate and said irregular surface of said natural effect panel (100).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features of the invention will be more readily understood and appreciated from the following detailed description when read in conjunction with the accompanying drawings of the preferred embodiment of the present invention, in which:

(2) FIG. 1 is a cross-section view of a natural effect panel in accordance to a preferred embodiment of the present invention;

(3) FIG. 2 is a perspective view of the natural effect panel;

(4) FIG. 3 is diagram illustrating a compression of a carved mould onto top and side including edge of the panel;

(5) FIG. 4 is a flow chart showing a method of fabricating the natural effect panel according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(6) As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for claims. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean including, but not limited to. Further, the words “a” or “an” mean “at least one” and the word “plurality” means one or more, unless otherwise mentioned. Where the abbreviations or technical terms are used, these indicate the commonly accepted meanings as known in the technical field. For ease of reference, common reference numerals will be used throughout the figures when referring to the same or similar features common to the figures. The present invention will now be described with reference to FIGS. 1-4.

(7) The present invention discloses an improvement of a furniture panel and the production of the panel which adds ornamentation value and natural effect. Said panel can be used for furniture such as tabletop and the like. More particularly, the present invention relates to a method of fabricating a natural effect panel (200), the method comprising the steps of: layering a resin impregnated paper sheet (101) as a base layer; depositing a layer of wood particles (102) on the base layer; dispersing the wood particles (102) evenly within a frame; layering a paper sheet (103) on the wood particles (102); compressing the wood particles (102) with the paper sheets (101, 103) to obtain an enwrapped composite board; layering a kraft paper (104), a decorative paper (105) and an overlay paper (106) by sequence on the composite board, wherein the kraft paper (104), the decorative paper (105) and the overlay paper (106) are resin impregnated; characterized by compressing the layered kraft paper (104), decorative paper (105) and overlay paper (106) to the top and side of the composite board with a carved mould under heat and pressure, thereby forming a natural effect panel (100) that having an irregular surface from top to the side including edge of the panel (100).

(8) FIG. 1 and FIG. 2 illustrate the natural effect panel (100) of the present invention, wherein the natural effect panel (100) comprises an irregular surface that form on top and side including edge of the panel (100). More particularly, the irregular surface covers top surface of the composite board and extends to side including edge of the composite board, thereby creating a natural effect that imitates a natural stone, marble or concrete that use to produce a tabletop or countertop of furniture.

(9) In a preferred embodiment of the natural effect panel (100), the irregular surface comprises a plurality of indentations uniformly form on the surface of the natural effect panel (100). The three layers including the kraft paper (104), the decorative paper (105) and the overlay paper (106) form a high pressure laminate (HPL). Each paper possesses different properties and functions which are known in the industry. In accordance to the present invention, the plurality of indentations is uniformly formed during fabrication process to form the irregular surface, thereby creating a natural effect that imitate natural stone, marble or concrete made furniture. Moreover, the irregular surface is not limited to the top of the panel but extended to the side of the panel including edge as in the present invention. Said formation of irregular surface at side panel is only achievable during formation of the laminate layer by simultaneously in a single step, which is compression by a carved mould. As such, said natural effect panel (100) may use as a replacement to the actual material which is heavy in nature.

(10) In a preferred embodiment of the natural effect panel (100), the carving of indentations is formed by a carved mould during the step of compressing the layered kraft paper (104), decorative paper (105) and overlay paper (106), wherein these papers form a layer of high pressure laminate. The mould encloses the composite board layered with the three papers on the top and the side, thus forming the irregular surface on top and side including edge of the panel (100) that improves the natural effect of the panel (100) as a whole, not only on the top surface but also to the side including edge at the angle of the panel.

(11) In a preferred embodiment of the natural effect panel (100), the composite board comprises a resin impregnated paper sheet (101), a layer of wood particles (102), and a paper sheet (103). The resin impregnated paper sheet (101) may be a kraft paper impregnated with resin. The wood particles (102) may be saw dust particles or the like. The paper sheet (103) may be any paper having pores and without resin or coating. The pores of the paper sheet (103) allows the paper sheet (103) to be breathable during compression, thereby reducing the crack of the paper that may be caused by the pressure during compression.

(12) In a preferred embodiment of the natural effect panel (100), the carving is formed on the top and side of the panel (100), wherein equal pressure is applied towards the top and side of the panel (100) to obtain a uniform carving pattern.

(13) FIG. 3 illustrates the moulding to carve the natural effect panel (100). As seen, the mould comprises protrusions that creates the indentations on top and side of the natural effect panel (100) by pressing the mould towards the high pressure laminate layer of the panel (100).

(14) In accordance to a preferred embodiment of the method (200) of fabricating the natural effect panel (100), a single pressing and moulding machine may be used to form the panel (100). Heat and pressure are applied during the compression to form the high pressure laminate layer onto the composite board while carving the surface of the layer.

(15) In a preferred embodiment of the method (200) of fabricating the natural effect panel (100), both laminating and carving are performed in a single step during compression.

(16) In a preferred embodiment of the method (200) of fabricating the natural effect panel (100), both compression steps are performed under high temperature of 18° C.

(17) FIG. 4 illustrates a flowchart of the method for fabricating the natural effect panel (100). The natural effect panel (100) as produced by the same method does meet the requirement for formaldehyde concentration in air from wood products using a small scale chamber of ASTM D6007-14; ISO 4892-3: 2006; BS EN 12720:2009+A1: 2013 Furniture Assessment of surface resistance to cold liquids; BS EN 12721: Resistance to wet heat; BS EN 12722: Resistance to dry heat; CPSD-HL-01055-MTHD: Surface Scratching. Further assessment has been tested including swelling in thickness after immersion in water and boil test which resulting 0.5% and 8.9% of original thickness of swelling after immersion in water and boiling water, while 53.5% change in weight for water absorption of boil test.

(18) The above natural effect panel (100) improves quality of a panel in the aspect of physical appearance which the panel (100) possesses an appearance that resemble stone, marble or concrete made panel. It gives the same feeling by touching the surface of the panel (100). Hence, said natural effect panel can replace the use of actual material including stone, marble or concrete, resulting an eco-friendly product by reducing reliance on natural resources that is non-renewable.

(19) Although the present invention has been described with reference to specific embodiments, also shown in the appended figures, it will be apparent for those skilled in the art that many variations and modifications can be done within the scope of the invention as described in the specification and defined in the following claims.

(20) Description of the reference numerals used in the accompanying drawings according to the present invention:

(21) TABLE-US-00001 Reference Numerals Description 100 Natural effect panel 101 Resin impregnated paper sheet 102 Wood particles 103 Paper sheet 104 Kraft paper 105 Decorative paper 106 Overlay paper 200 Method of fabricating the natural effect panel