MBR001_PCT

Description of Industrial Invention entitled:

"METHOD FOR MAKING AN ORNAMENTAL PANEL, AND PANEL OBTAINED WITH SAID METHOD"

DESCRIPTION

The present invention relates to a method for making an ornamental panel.

The present invention further relates to an ornamental panel made by using said method.

As is known, ornamental panels are often used in the architecture and furniture field to characterize indoor and outdoor environments.

In this frame, the Applicant wanted to provide an innovative ornamental panel, made by following a method just as original.

In accordance with a first aspect, the invention relates to a method for making an ornamental panel.

Preferably, the method comprises providing a main body in board form.

Preferably, the method comprises providing a plurality of optic fibers, capable of transmitting light through their lateral surface.

Preferably, the method comprises applying a first layer of plastic material onto a front surface of said main body.

Preferably, the method comprises applying, before said first layer is dry, said optic fibers onto said first layer.

Preferably, the method comprises applying, before said first layer is dry, a second layer of plastic material onto said optic fibers.

Preferably, the method comprises removing, before said first and second layers are dry, excess plastic material to clear part of said optic fibers.

In accordance with a second aspect, the invention relates to an ornamental panel made by using the above-described method. In one or more of the above aspects, the invention may comprise one or more of the following preferred features.

Preferably, the method comprises a step of applying a primer onto said front surface prior to applying said first layer.

Preferably, the method comprises: a) making a plurality of through holes in said main body.

Preferably, the method comprises: b) threading said optic fibers through said holes.

Preferably, said steps a) and b) are carried out prior to applying said first layer.

Preferably, the method comprises, after steps a) and b) and before applying said first layer, arranging the optic fibers in a substantially elongate condition on said front surface.

Preferably, the method comprises, after steps a) and b) and before applying said first layer, fixing the free ends of said optic fibers to a supporting element.

Preferably, the method comprises, after steps a) and b) and before applying said first layer, removing the optic fibers from the front surface by moving said supporting element.

Preferably, the method comprises fixing said optic fibers in said holes.

Preferably, the longitudinal axis of said holes is transversal to the planar development of the main body.

Preferably, said holes are substantially frustoconical, with their major base on the front surface.

Further features and advantages will become more apparent in the light of the following detailed description of a preferred, but non-limiting, embodiment of the invention. Such description is provided herein with reference to the annexed drawings, which are also supplied by way of nonlimiting example, wherein: - Figure 1 schematically shows a front view of an ornamental panel in accordance with the present disclosure;

- Figure 2 schematically shows a partial side view of the panel of Figure 1;

- Figure 3 shows a step of the process of making the panel of Figure i;

- Figure 4 schematically shows a detail of the panel of Figure 1;

- Figure 5 schematically shows some elements of the panel according to the present invention, not shown in Figure 1.

With reference to the annexed drawings, numeral 1 designates as a whole an ornamental panel in accordance with the present invention.

The panel 1 comprises, first of all, a main body 10 (Figure 1-3).

The main body 10 is made in board form.

The material used for the main body may be, for example, wood; in particular, the so-called MDF, Medium Density Fibreboard, may be used. As an alternative, a rigid polyurethane foam material (PUR/PIR) may be used, known under the commercial name "purenit". The data sheet of this material is available at the following address: https://www.purenit.it/wp- content/uploads/2021/ll/purenit IT 2019.pdf (last visit on September 30, 2022).

As far as the main body 10 is concerned, the Applicant observes that any rigid material may be used as a support which maintains the design shape and dimensions and which has the technical and mechanical characteristics required of a vertical covering panel.

If necessary, the main body 10 may be cut to size, depending on the application.

The main body 10 may generally have an arbitrary shape. By way of example, and solely for the purpose of describing the following illustrative embodiment, a main body will be considered which has a substantially rectangular perimetric profile (in a plan view).

The panel 10 has a front surface 10a and a back surface 10b.

As will be further detailed hereinafter, a plurality of optic fibers 20 are applied onto the panel 10. Such optic fibers 20 are made/processed in such a way as to be substantially transparent to light also on their (cylindrical) lateral surface. This characteristic is obtained with a specific physicalchemical treatment called "side-light". In this manner, when light is injected from one end of an optic fiber, the light will be visible not only at the opposite end, but also along the entire longitudinal extension of the fiber.

Thus, under dark or poorly lit conditions the optic fibers can be illuminated, thereby creating a special and characterizing aesthetic effect.

The main body 10 is initially coated with a layer of primer 100'; one may use acrylic or vinyl primers, depending on the nature of the panel support, quartz primers (for increased grip and adhesion power), with high adhesion resistance; by way of example, one may consider the products known under the commercial name "Terragrip" by MatteoBrioni Sri and/or "Eco Prim Grip Plus" by Mapei Spa. In this way, a surface is prepared which will ensure optimal grip for the layers to be subsequently applied.

In particular, the primer is applied onto the front surface 10a of the main body 10.

Preferably, during this step and in the next steps, which will be described below, the main body 10 is kept substantially horizontal.

The main body 10 is subjected to a milling operation.

During the milling operation, a plurality of through holes 11 are made in the main body 10.

Advantageously, the longitudinal axis of the holes 11 (Figure 4) is transversal to the planar development of the main body 10.

Advantageously, the holes 11 comprise a draft giving the holes 11 a substantially frustoconical conformation. In this way, the optic fibers 20 can be threaded from the back to the front of the main body 10 without generating tight bends.

For example, the inclination of the longitudinal axis of the holes 11 with respect to the planar development of the main body 10 may range between 30 and 45 degrees, e.g. 35 degrees.

The frustoconical shape of each hole 11 may have a major base with a diameter ranging from 10 to 25 mm, e.g. 15 mm, and a minor base with a diameter ranging from 4 to 10 mm, e.g. 6 mm.

Preferably, the number of drilled holes 11 may range from 10 to 50, e.g. about 30. In principle, the distance between the holes should be in the range of 5 to 10 cm, e.g. 7 cm. Of course, this parameter depends on the type of application; therefore, the number of holes may also be different.

The milling operation can be carried out prior to the application of the primer, in particular in order to allow the primer to coat also the inside of the holes.

The holes 11 may be made in any position of the main body 10, depending on where the optic fibers 20 will have to be inserted. Merely by way of example, an embodiment is conceivable wherein the holes 11 are made along a straight line substantially parallel to the minor side of the rectangular profile of the main body 10.

The optic fibers 20 are then threaded through the holes 11.

It should be noted that the optic fibers 20 typically extend from a collector 30 (which will be further described below) and are arranged in a bundle approximately cylindrical in shape. The optic fibers 20 are then distributed horizontally, with a sort of "combing" action to separate them from one another. The optic fibers 20 are then collected into small groups (e.g. about five fibers per group); the fibers of each group are held together by means of suitable fastening elements, such as cable ties or adhesive tape. Each group of optic fibers 20 is then inserted through a respective hole 11, so that the free end of each fiber will reach the front surface 10a of the main body 10.

In one embodiment, the fibers may have, in sequence, three or four different lengths, which are repeated according to a specific sequence/algorithm depending on the desired aesthetic effect to be obtained along the entire width of the main body 10. It must however be reminded that different solutions may also be adopted, depending on the desired final effect.

Once threaded through the holes 11, the optic fibers 20 are laid onto the main body 10 and kept in a substantially elongate condition. It should be noted that, due to their very conformation and structure, optic fibers are naturally prone to bending.

In particular, the optic fibers 20 are laid onto the front surface 10a of the main body 10.

In order to keep the optic fibers 20 in a substantially elongate condition, a supporting element 40 (Figure 3) may be used, e.g. a simple piece of wood, having a size approximately equal to or greater than the minor side of the main body 10.

The free end of the optic fibers 20 is removably constrained to said supporting element 40, e.g. by means of adhesive tape.

The supporting element 40 is then located in a distal position relative to the holes 11, so as to keep the optic fibers 20 in the desired condition.

At the holes 11, the optic fibers 20 are fixed by means of adhesive material, e.g. silicone, which will fill and seal the previously milled hole. Thus, the optic fibers 20 will no longer be allowed to slide within the holes 11.

The optic fibers 20 are then moved away from the surface of the main body 10, while however remaining constrained to the supporting element 40. This will be useful during the next step of laying the optic fibers 20. Once the front surface 10a of the main body 10 has been cleared of the optic fibers 20, a first layer 100 of plaster is deposited onto the front surface 10a (Figure 2).

The material used for the first layer 100 may be formed of:

- a certain quantity of fine clay-based plaster;

- addition of 10% by weight, relative to said certain quantity, of mineral plaster reinforced with specific polymers;

- addition of 20% by weight, relative to said certain quantity, of water.

The total quantity of material varies as a function of the dimensions of the main body 10.

In general, the Applicant observes that the first layer 100 should have a thickness of approximately 3-4 mm, i.e. at least twice the diameter of the optic fiber (e.g. 1 mm), to allow the latter to be "buried" in the first layer 100.

The above-indicated composition of the first layer 100 is merely illustrative; a different material may be used as well, provided that it has sufficient plastic properties to incorporate the optic fibers 20, as will be described below.

Said material, having the consistency of a plastic mortar, will have to be spread with a spatula, a square trowel and/or any other tool suitable for completely coating the surface of the main body 10. The evenness of the application thickness will determine the regularity of the aesthetic appearance of the final panel.

Optionally, the application of the first layer 100 may be preceded by the creation of a "wave" or "dune" effect on the front surface 10a of the main body 10. Such an effect can be obtained by depositing some material (e.g. the same material to be used afterwards for the first layer 100) onto individual zones of the front surface 10a. Once the effect is created, e.g. when the "dunes" are dry, it will be possible to start depositing the first layer 100.

After the first layer 100 has been deposited, and before the material is dry, the optic fibers 20 are repositioned on the main body 10 and "buried" in the mortar layer.

Preferably, the supporting element 40 is picked up and placed again in the previous position, so as to bring the optic fibers 20 back into the elongate condition on the main body 10.

With the optic fibers 20 in this condition, by means of a suitable tool (e.g. a spatula) the optic fibers 20 are buried in the first layer 100. Pliers may also be used in order to pick up and arrange the individual fibers in the desired pattern.

In order to hold the optic fibers 20 in the correct position in proximity to the holes 11, heavy objects may be used (e.g. unused spatulas).

In order to complete the insertion and coating of the optic fibers 20, a second layer 200 of material is applied. For the second layer 200, a material which is similar or equal to the one employed for the first layer 100 may be used.

The deposition of the second layer 200 is carried out before the first layer 100 is dry.

In technical jargon, this is a "wet-on-wet" application, which ensures an optimal incorporation of the fibers into the plastic material.

After the material of the second layer 200 has completed a short initial drying phase (e.g. 10 to 50 minutes, depending on the atmospheric conditions and the type of material employed), by using a suitable tool such as, for example, a spatula, preferably made of plastic to avoid scratching the optic fibers and impairing their brightness, the excess material is removed to clear significant portions of optic fiber. From a practical viewpoint, this step is carried out when the material of the second layer 200 is just starting to "set", i.e. when it is still soft and can be modified/pressed/stretched/removed, but has already lost the evaporating surface water and can be worked without sticking to the spatula.

It is then necessary to wait for the materials to dry completely, e.g. about one day (12/24 hours).

At this point, it is possible to perform a light sanding operation to finish the removal of the excess material.

Further optional operations may also be carried out, such as, for example:

- application of an additional self-smoothing material layer; this is a very thin layer, to be applied in very liquid (diluted) condition by means of a rubber spatula after slightly wetting the underlying material;

- application of additional ornamental layers, using materials similar to those employed for the first layer 100 and the second layer 200;

- creation of additional aesthetic effects, e.g. glazing, sponging, carving, graffiti, etc.

In general, the Applicant observes that the holes 11 should preferably be made prior to applying the first layer 100; in fact, the milling operation causes dispersion of a lot of dust that would otherwise contaminate the material of the first layer 100, which, as aforesaid, must be worked before it is completely dry. Moreover, the making of the holes 11 takes some time, which may delay the process and cause the optic fibers 20 to be laid when the first layer 100 has already dried too much.

In order to hang or anyway fix the panel 1 to a wall, suitable hooking elements (e.g. racks) can be fastened to the back surface 10b; the type, dimensions and number of the hooking elements may vary according to the dimensions of the panel and the type of application. In particular, the number of hooking elements should preferably be selected to maintain the planar conformation of the panel 1 and prevent it from bending.

As far as the illuminating part is concerned, the optic fibers 20 are, as aforementioned, fixed to a collector 30 (Figure 5). The latter is removably constrained to an illuminating body 50 (e.g. a LED lamp). When power is supplied to the illuminating body 50, the light is collected by the optic fibers 20 and, as aforesaid, emitted along the entire longitudinal development of the same.

The removable constraint between the collector 30 and the illuminating body 50 makes it easy to carry out maintenance and/or replacement work.