DECORATIVE PLASTIC PANEL AND METHOD OF FABRICATING DECORATIVE PLASTIC PANELS

Abstract

An additive system for use in a polymeric formulation (plastic) that includes a plurality of visually differentiable elongated streaks contained in a mono-colored base, the visually differentiable elongated streaks are composed of a pigmented material having a random pattern and elongated due to the manufacturing process. The visually differentiable streaks are composed of at least two colors, each having a pigment shade visually differing from one another. The visually differentiable streaks are elongated and randomized during the manufacturing process to resemble the elongated markings present in natural materials such as marble or wood. The visually differentiable markings can be utilized in various color combinations to make lightweight useful articles having a pleasing aesthetic appearance.

Claims

1. A decorative plastic panel resembling stone comprising: a hollow panel having a front wall, a rear wall, a pair of side walls, and a pair of end walls, the walls joined along their respective edges to construct the hollow panel, an outer surface of each wall including a decorative layer of plastic, the decorative layer including at least two visibly differentiable colors, a first color being a base color forming a preponderance of the decorative layer, a second color forming elongated streaks, the elongated streaks extending parallel to a longitudinal axis of the decorative panel and each elongated streak having different lengths and random positions with respect to other elongated streaks.

2. The decorative plastic panel of claim 1 wherein the decorative layer of plastic includes three or more visibly differentiable colors, wherein two or more of the differentiable colors are elongated streaks on the outer surface of the decorative panel.

3. The decorative plastic panel of claim 1 wherein the plastic used to form the elongated streaks has a higher melting point than the plastic forming the base color.

4. The decorative plastic panel of claim 3 wherein the elongated streaks are formed from shaped particles of plastic material during an extrusion process, the extrusion process elongating the plastic particles.

5. The decorative plastic panel of claim 4 wherein the length of the elongated streak is determined by the plastic particle size.

6. The decorative plastic panel of claim 4 wherein the shaped particles are cut cylinders.

7. The decorative plastic panel of claim 4 wherein the shaped particles are spheres.

8. The decorative plastic panel of claim 4 wherein the shaped particles are discs.

9. The decorative plastic panel of claim 3 wherein the elongated streak forming particles of plastic have at least a 10 degree Celsius higher melting point than the plastic particles forming the base color.

10. The decorative plastic panel of claim 4 wherein the width and length of the elongated streak is determined by the orientation of the plastic particle.

11. The decorative plastic panel of claim 3 wherein the elongated streak forming particles of plastic have at least a 25 degree Celsius higher melting point than the plastic particles forming the base color.

12. The decorative plastic panel of claim 3 wherein the elongated streak forming particles of plastic have at least a 40 degree Celsius higher melting point than the plastic particles forming the base color.

13. A method of forming a decorative plastic panel to resemble stone comprising: providing a first color of plastic particles for use as a base color; providing a visibly differentiable second color of plastic particles; mixing the first color of plastic particles and the second color of plastic particles; placing the mixed plastic particles in a hopper for an extrusion machine; extruding the first and second plastic particles to form a hollow parison, wherein the second color of plastic forms elongated streaks on the outer surface of the parison.

14. The method of forming a decorative plastic panel of claim 13 including providing a blow molding die, wherein the blow molding die is closed on the parison before compressed air is introduced into the parison to cause the parison to expand to the form of a cavity in the blow molding die, allowing the formed parison to cool sufficiently to retain the shape of the die cavity before opening the die.

15. The method of forming a decorative plastic panel of claim 13 including the step of providing a third color of plastic particles, the third color plastic particles being visibly distinctive from the first and second color plastic particles.

16. The method of forming a decorative plastic panel of claim 13 wherein the second color plastic particles include a shape, the shape altering the appearance of the elongated streak.

17. The decorative plastic panel of claim 16 wherein the shaped particles are cut cylinders.

18. The decorative plastic panel of claim 16 wherein the shaped particles are spheres.

19. The decorative plastic panel of claim 16 wherein the shaped particles are discs.

20. The method of forming a decorative plastic panel of claim 15 wherein the third color plastic particles include a shape, the shape altering the appearance of the elongated streak.

21. The decorative plastic panel of claim 20 wherein the shaped particles are cut cylinders.

22. The decorative plastic panel of claim 21 wherein the shaped particles are spheres.

23. The decorative plastic panel of claim 21 wherein the shaped particles are discs.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0033] FIG. 1 is a front view of a wall panel for a shed, illustrated with integrally formed connections on each side for connection to other panels;

[0034] FIG. 2 is a front view of a plurality of extrusion blow molded panels illustrating the random pattern produced by the present method;

[0035] FIG. 3 is a top left front perspective view illustrating a panel having the elongated streak pattern utilized as a counter top;

[0036] FIG. 4 is a top left rear perspective view of the embodiment illustrated in FIG. 3;

[0037] FIG. 5 is a partial cross section view taken along lines 5-5 of FIG. 1 illustrating the tack offs;

[0038] FIG. 6 is a partial perspective view of a panel of FIG. 5, separated to illustrate the construction of the tack offs and the connection to the opposite panel;

[0039] FIG. 7 is a partial view illustrating the front and rear walls of a panel separated to show the construction and connection of the tack offs;

[0040] FIG. 8 is a top rear perspective view illustrating the layout of the tack offs; and

[0041] FIG. 9 is a perspective view illustrating the inner wall of the plastic panel.

DETAILED DESCRIPTION OF THE INVENTION

[0042] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred, albeit not limiting, embodiment with the understanding that the present disclosure is to be considered an exemplification of the present invention and is not intended to limit the invention to the specific embodiments illustrated.

[0043] Referring to FIGS. 1-9, a decorative plastic panel 100 resembling stone is illustrated. The plastic panel 100 is preferably formed as a hollow panel having a front wall 10, a rear wall 12, a pair of side walls 14, a top end wall 16, and a bottom end wall 18. The walls are integrally joined along their respective edges 20 to construct the hollow panel. An outer surface 22 of each wall includes a decorative layer of plastic that includes at least two visibly differentiable colors; a first color 24 being a base color forming a preponderance of the decorative layer, and a second color 26 forming elongated streaks, the elongated streaks extending parallel to a longitudinal axis of the decorative panel and each elongated streak having different lengths and random positions with respect to other elongated streaks. In addition, the elongated streaks may be darker or lighter in color with respect to the first color, and some embodiments include a third color 28 also formed as elongated streaks extending parallel to the longitudinal axis 30. In the preferred embodiment, the decorative layer of plastic includes three or more visibly differentiable colors, wherein two or more of the differentiable colors are elongated streaks on the outer surface of the decorative panel with the first base color forming the background. The decorative plastic panels 100 may be used for numerous decorative purposes, some of which include counter tops for outdoor bars, table tops, furniture, deck boxes, and outdoor sheds to name a few. In general, the plastic panels 100 can be used in any place where a blow molded panel can be used. The plastic panels are preferably formed by extrusion of plastic pellets followed by blow molding to shape the extruded parison before it cools and hardens forming a hollow component formed of relatively thin outer walls. The outer walls of the preferred embodiment are less than one eighth of an inch thick and may be one sixteenth of an inch thick or less. To provide stiffness to the hollow panels, they may be provided with a plurality of tack-offs. The tack-offs 32 are an indention 34 of the extruded plastic that extends from one of the separated walls to another wall, wherein a portion of the indentation 34 forms an attachment 36 to the inner surface of the other wall. The tack-offs 32 may take almost any shape, so long as an attachment is formed between the two walls of the panel. This construction preferably leaves one wall smooth and free from indentations 34 for use, while a lower or back surface includes the indentations 34 and provides rigidity to the panel. At least some embodiments include tack-off indentations 34 extending inward from both sides of the panel where portions of the panel are hidden to maintain the appearance of the stone or wood on the visible portions of the panel. The edges 20 of the panel 100 may be provided with means for attaching one panel to another.

[0044] Still referring to FIGS. 1-9, a method for forming a decorative plastic panel having an outer layer of plastic that resembles stone or wood will be described. In general, a plastic extruder blow molding machine includes a hopper which accepts plastic particles, granules and the like. In the present process, plastic particles that include a first color for use as a base color are mixed with plastic particles of a second color and, in some embodiments, plastic particles having a third or even a fourth or more color are placed into the hopper. The different colors are visibly differentiable with respect to each other to provide a color contrast on the plastic panel. The plastic particles are allowed to feed via gravity to an extrusion screw which rotates to compress, kneed and heat the plastic particles. A portion of the heat occurs from the compression and heating, while a portion of the heat may be provided by various types of heating elements or induction heating. The semi-molten plastic is directed through an extrusion head where the walls are formed as a parison, e.g. a long hollow tube of plastic elevated to a temperature that causes the particles of plastic to bond together and homogenize. The present invention places particles that have a sufficiently different melting temperature that do not homogenize when flowing through the extruder screw, and instead reach a sufficient temperature to cause the second and third color particles to elongate along the surface and through the parison, creating the elongated streaks of different colors. In a preferred embodiment, the second and third color plastic particles include a shape, the shape altering the appearance of the elongated streak. Thus, the plastic particles may include cut cylinders, spheres, discs and the like geometric shapes that include different dimensions as the object is rotated. It is also preferred that the plastic particles used to form the elongated streaks include a higher melting point than the plastic forming the base color. In at least one embodiment, the plastic particles used for the elongated streaks have at least a 10 degree Celsius higher melting point than the plastic particles forming the base color. In other embodiments, the plastic particles used to form the elongated streaks have at least a 25 degree Celsius higher melting point than the plastic particles forming the base color; and in still another embodiment, the elongated streak forming particles of plastic have at least a 40 degree Celsius higher melting point than the plastic particles forming the base color. In this manner, the shape and orientation of the particle causes elongated streaks with different widths and lengths similar to natural stone and wood. The temperature of the particles is sufficient to allow the different materials to bond and blend together along the edges of the elongated streaks. A blow molding die is closed on the parison before compressed air is introduced into the parison to cause the parison to expand to the form of a cavity in the blow molding die, allowing the formed parison to cool sufficiently to retain the shape of the die cavity before opening the die.

[0045] Referring generally to the figures, and more specifically to FIGS. 3 and 4, the plastic panel 100 is illustrated in use as a counter top for a bar. The plastic panel 100 provides an appealing surface with the appearance of stone, such as marble, without the weight of real stone or the difficulty of manufacture. It should also be noted that while the present specification refers to the term plastic, resins and the like typically used in the plastics industry are also included herein.

[0046] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

[0047] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

[0048] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.