Device and process for fabricating aesthetic wall coverings

Abstract

A tool for manufacturing a molded pulp wall covering is disclosed. The tool includes a flat tool base, a flat screen attached to the tool base, and a patterned grid that is removably attached to the tool base in a position over the flat screen. The shape of the removable attached patterned grid is used to shape the molded pulp wall panel produced by the tool. Different removable patterned grids may be used on the same flat tool base to produce wall panels with different shapes and patterns.

Claims

1. A tool for use in making aesthetic wall coverings by pulp molding comprising: a flat tool base; a flat screen attached to said base; and a patterned grid removably attached to said tool base in a position over said flat screen.

2. The tool according to claim 1, wherein said tool base is porous.

3. The tool according to claim 1, wherein said patterned grid is comprised of a plurality of grid members forming a pattern.

4. The tool according to claim 1, further comprising a locator element.

5. The tool according to claim 4 where said locator element is a peg extending out from said flat screen.

6. The tool according to claim 1, wherein said patterned grid is configured to replicate cement block, brick, or tile.

7. The tool according to claim 1, further comprising caulk located on said flat screen and adjacent to said patterned grid.

8. The tool according to claim 1, wherein said tool base is made of steel or aluminum.

9. The tool according to claim 1, wherein the flat screen is made of material comprising copper.

10. The tool according to claim 1, wherein said tool base further comprises a plurality of drain holes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The foregoing and other aspects and advantages of the present invention will be better understood from the following detailed description of exemplary embodiments of the invention with reference to the drawings in which:

(2) FIG. 1 illustrates perspective view of the elements forming an exemplary wall covering according to the present invention;

(3) FIG. 2 illustrates a front elevational view of the elements forming an exemplary wall covering according to the present invention;

(4) FIG. 3 illustrates a front elevational view of an exemplary wall covering according to the present invention;

(5) FIG. 4 a sectional side view of an exemplary wall covering according to the present invention taken at line 4-4 in FIG. 3;

(6) FIG. 5 illustrates a front elevational view of the elements forming an alternative embodiment of an exemplary wall covering according to the present invention;

(7) FIG. 6 illustrates a block flow diagram of the steps used in the manufacturing method according to the present invention;

(8) FIG. 7 illustrates a block flow diagram of the steps used in the manufacturing method according to the present invention;

(9) FIG. 8 illustrates a sectional side view of a jig taken along line 8-8 of FIG. 7;

(10) FIG. 9 illustrates a perspective view of a fabrication tool according to the prior art;

(11) FIG. 10 illustrates a partial sectional view of a fabrication tool according to the prior art;

(12) FIG. 11 illustrates a perspective view of a fabrication tool according to the present invention;

(13) FIG. 12 illustrates a partial sectional view of a fabrication tool according to the present invention;

(14) FIG. 13 illustrates a plan view of a patterned grid for use in conjunction with a fabrication tool according to the present invention, and

(15) FIG. 14 illustrates how different patterned grids may be used with the same tool base and screen in a fabrication tool according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(16) In the following description of the invention, reference is made to the accompanying drawings, which form a part thereof, and in which is shown, by way of illustration, exemplary embodiments illustrating the principles of the wall covering and method of manufacturing of the present invention and how it may be practiced. It is to be understood that other embodiments may be utilized to practice the present invention and structural, functional, and procedural changes may be made thereto without departing from the scope of the present invention.

(17) A wall covering in accordance with a first embodiment of the present invention is illustrated in FIGS. 1-4 and is generally designated by the numeral 10. Wall covering 10 may include one or more elements 12 that can be used together to form a desired pattern on a wall 24. It will be understood by those having ordinary skill in the art that the wall covering 10 may be used in conjunction with a vertical wall 24 as well as on ceilings, floors or angled surfaces as well.

(18) Each element 12 includes front or display surface 14, rear surface 16 and edges 20. Display surface 14 includes surface pattern 18, which, in the example illustrated in FIGS. 1-4, depicts a brick surface. Adjoining elements 12 are fitted together at joints 22, as best illustrated in FIG. 3, such that no gaps appear between adjacent elements 12.

(19) The wall coverings according to the present invention and as depicted in the drawing figures are not intended to be in any way limited in size, shape or patterns to those illustrated. It will be understood by those having ordinary skill in the art that wall coverings according to the present invention may be of various shapes and patterns.

(20) FIG. 5 illustrates wall covering 10 having a surface pattern 18 that simulates a rock wall. Surface pattern 18 may be created by a number of methods of surface preparation on display surface 14, such as sanding, carving, or embossing, and other details may be painted or digitally printed on display surface 14.

(21) A wall covering 10 according to the present invention may be made with a variety of thicknesses depending on the application and can be controlled by the slush molding process. The fabrication of a wall covering 10 according to the present invention by the use of slush molding results in a wall covering 10 having a rough uneven display surface 14 and a moderately rough uneven rear surface 16. Such a configuration is not conducive to the use of conventional adhesives to attach wall covering 10 to surface 24. Wall covering 10 and the elements 12 that are used to form it may be attached to surface 24 by means of conventional fasteners such as nails, screws, staples or tape.

(22) FIG. 6 illustrates the steps of the method of manufacturing of a wall covering 10 in accordance with the present invention. The method of manufacturing incorporates the use of a specially designed jig 40, which is illustrated in FIGS. 7 and 8. Jig 40 includes a support surface 42, which secures and positions each element 12 as it undergoes digital printing on a flatbed printer during manufacturing. Support surface 42 includes a shaped perimeter 44 that is designed to follow the edges of element 12. Preferably support surface 42 is a foam core material to provide a close fit between jig 40 and element 12. Jig 40 makes the element 12 air tight during printing and provides consistent positioning of the elements and holds them flat.

(23) Lower surface 46 of jig 40 is stretched and fixed to support surface 42. Preferably, lower surface 46 is made of a thin flexible plastic, such as Sintra. Lower surface 46 includes openings 48 to allow for suction to hold an element 12 stable and flat during printing. The printer used during the method according to the present invention is most effective on flat surfaces, and jig 40 allows the printer to print more effectively on display surface 14. Without the use of jig 40, the printer used during the method of manufacturing according to the present invention could be damaged, which would be expensive to repair.

(24) Once it is determined what the desired appearance of a wall covering 10 should be, the first step 100 is to prepare a mockup or model of the desired wall covering 10 or element 12. From the model, at step 102, a molding tool and conforming screen are prepared. The tool is generally made of a composite material and includes the desired surface pattern depicted by the mockup. The screen is generally of a porous copper construction and is shaped to conform to the surface pattern formed by the tool. It may be necessary, for certain surface patterns, to remove portions of the screen to preserve the integrity of the screen and the surface pattern.

(25) At step 104, a slurry blending recycled paper, cardboard and water is prepared. At step 106, the slurry is pumped into a vat in the slush molding machine where the tool is immersed in the slurry. As the level of the tool rises, the slush molding machine uses suction to remove the slurry water from the tool and screen. Thickness of the wall covering 10 is determined during this step by monitoring and controlling the amount of slurry injected into the tool and screen.

(26) At step 108, once the slush molding process is completed, wall covering 10 is removed from the slush molding machine and conveyed to a dryer. At step 110, the user then makes a decision whether to divide wall covering 10 into a plurality of elements 12, either by use of Computer Numerical Control (CNC) cutting, step 112 (which may be by means of a water jet, an oscillating knife, a rotating blade or a laser), or alternatively, by die cutting, step 114. Use of the cutting step 112 or 114 forms edges 20 that configure joints 22 so that elements 12 fit closely together, leaving no gaps, and does not require joints 22 to be caulked.

(27) At step 116, display surface 14 of each element 12 is finished and the surface pattern 18 is formed by using a variety of procedures, such as sanding, carving, embossing or the like to create the desired and realistic surface pattern 18 envisioned at the beginning of the process.

(28) At step 118, each element 12 is secured in jig 40 in preparation for printing. Each jig 40 must be designed for a particular element 12 and surface pattern 18.

(29) Step 120 in the production process may include digitally printing colors and surface features on display surface 14 to provide further details to surface pattern 18.

(30) The completed elements 12 of wall covering 10 can be mounted to wall 24 by use of conventional fasteners 26, such as screws, nails, staples, tape, Velcro and the like, form wall covering 10.

(31) In another aspect of the present invention, the inventors have developed a reusable and interchangeable tool for use in the slush molding process to create aesthetic wall coverings 10. The conventional tool 60, also noted as prior art, is illustrated in FIGS. 9 and 10. A shaped poured tool base 62 includes drain holes 66 for water removal during the slush molding process. Screen 64 is configured to fit the various shapes in tool base. Screen 64 and poured tool base 62 together form the conventional tool 60 that is used, Such contouring is time consuming and labor intensive and much of it must be done by hand. Screen 64 is then physically attached to the shaped poured tool base 62 by means of soldering between the screen and conventional connectors 70 inserted in shaped poured tool base 62, such as screws, attached to the tool base 62. Screen 64 will retain the pulp while water is suctioned out of the drain holes 66 during the pulp molding process.

(32) Conventional tool 60 is specifically made for a specific design of wall covering 10. For example, if a wall covering 10 simulating bricks is desired, tool 60 may be used only for such a design.

(33) FIGS. 11-14 illustrate an embodiment of new improved tool 160 for use in the slush molding process in accordance with the present invention. Tool 160 includes a flat porous tool base 162 having drain holes 166. The porous tool base 162 could be made of steel, aluminum or a pourable material, for example. Screen 164 is attached to porous tool base 162 by means of conventional methods, such as soldering, conventional connectors, such as screws inserted in porous tool base 162. Note that in tool 160, screen 164 is not manipulated to conform to particular shapes but is instead is flat when attached to porous tool base 162, thus substantially reducing the labor time required to form tool 160 compared to prior art tool 60.

(34) Once screen 164 is attached to porous tool base 162, patterned grid 172 consisting of grid members 174 is placed on top of screen 164 and attached by attachment means 170 (which may be one of several conventional types of attachment means, such as screws). Caulking 176 is used to fill in gaps where grid members 174 fit on top of screen 164 to prevent unwanted buildup of slurry in these gaps during the process of manufacturing.

(35) Grid 172 provides the desired shape of wall covering 10, such as a brick or tile surface. Once the desired wall covering 10 is produced, as illustrated in FIG. 14, patterned grid 172 (which for purposes of illustration is shown in a brick pattern) may be detached from porous tool base 162 and screen 164 and replaced by an alternative patterned grid 178 (which for purposes of illustration is shown in a flagstone grid) and attached as discussed. Thus, tool 160 provides great versatility and may be reused to create a new pattern of wall covering 10. Tool 160 provides a substantial cost and time savings over the prior art tool 60, which requires the creation of a separate new tool, with a poured shaped tool base 62 and a screen 64 shaped to conform to the contours of poured shaped tool base 62 for each design of wall covering 10. Locator peg 180 is used during the die cutting of parts to ensure proper alignment and precise dimensioning of finished wall covering elements.

(36) The buildup of material on the patterned grid 172 is not as thick on the forming screen 164, which advantageously provides finished wall coverings which are more flexible and may be attached to a curving wall, are flatter for digital printing, and flatter for shipping and storing, thus saving space. Patterned grid 172 enables the formation of aesthetic details, for example, the grout lines in a brick or block wall aesthetic wall covering. The inventors have also found that by adding a surplus of pulp surrounding the various patterned grids beyond the intended finished die-cut patterned design of the wall covering solves the problem of parts warping and potato chipping as they free dry on the conveyor belt going through the drying oven. The dimensions of the dried parts have to be accurate in order to die cut them properly. Creating aesthetically correct and pleasing wall coverings using slush molding raises problems not found in making the usual packaging products made by slush molding for the packaging industry, in that the wall coverings must fit together precisely with high tolerance in dimensions and detail. Porous screen tool base 162, flat screen 164, and patterned grid 172 in combination comprise the improved tool 160 according to the present invention.

(37) The advantages provided by the improved fabrication tool in accordance with the present invention for slush molding of aesthetic wall coverings include the ability to have consistent production with dimensionally accurate parts; providing a flat front surface when the detail is required; providing better control over part finishing in that the parts lay flat for printing and shipping; reduced tooling costs; reduced wear and tear on the tooling; and reduction in energy use and material waste during production.

(38) The foregoing descriptions of exemplary embodiments of the present invention and the methods of manufacture have been presented for purposes of enablement, illustration, and description. It is not intended to be exhaustive of or to limit the present invention to the precise forms discussed. There may be, however, other wall covering methods of manufacture, fabrication tools, and molded pulp products not specifically described herein, but with which the present invention is applicable. The present invention should therefore not be seen as limited to the particular embodiments described herein; rather, it should be understood that the present invention has wide applicability with respect to molded pulp products. Such other configurations can be achieved by those skilled in the art in view of the description herein. Accordingly, the scope of the invention is defined by the following claims.