IP Library › Granted Patent US 9,881,727
Granted Patent B2
US 9,881,727 · App. 14/881,698 · Granted Jan 30, 2018

Decorative multi-layer surfacing materials having embedded conductive materials, solid surfaces made therewith, methods for making such surfacing materials and uses therefor

Inventors: Kevin Francis O'Brien (Cincinnati, OH); Bryce Lamar Cole (Mason, OH); Robert Jacob Kramer (Franklin, OH)
Assignee: The Diller Corporation
H01F27/2804H01F27/24H01F38/14H01F41/041H02J5/005H01F2027/2809H02J7/0042H02J7/025
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Quick Facts
Patent No.
US 9,881,727
App. No.
14/881,698
Granted
Jan 30, 2018
Kind
B2
Abstract

Decorative, multi-layer surfacing materials, surfaces made therewith, methods of making such and wireless power transmission using the same, which surfacing materials comprise: a first resin-impregnated paper layer and a second resin-impregnated paper layer, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus; wherein the first conductive material is disposed on a first surface of the first resin-impregnated paper layer; wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer; and wherein at least one of the first resin-impregnated paper layer, the second resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer.

Claims (17)

1. A method of wirelessly transmitting energy, the method comprising: (i) providing a decorative, multi-layer surfacing material comprising: a first resin-impregnated paper layer and a second resin-impregnated paper layer, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus; wherein the first conductive material is disposed on a first surface of the first resin-impregnated paper layer; wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed relationship such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer; and wherein at least one of the first resin-impregnated paper layer, the second resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer; (ii) providing electrical current to the first conductive material such that an electromagnetic field is generated in a region adjacent to the surfacing material; and (iii) placing a device configured to receive wireless energy transmission proximate to the surface and within the electromagnetic field.

2. The method according to claim 1 , wherein the decorative, multi-layer surfacing material further comprises at least one outer protective layer.

3. The method according to claim 2 , wherein the at least one outer protective layer comprises a polymer selected from the group consisting of acrylics, polyesters, melamine resins, vinyl resins, and urethanes.

4. The method according to claim 2 , wherein the at least one outer protective layer comprises a melamine resin.

5. The method according to claim 1 , wherein the decorative layer comprises a visual attribute selected from the group consisting of colorings, patterns, indicia, pictures, embedded objects, and combinations thereof.

6. The method according to claim 1 , wherein the first conductive material disposed on the first surface of the first resin-impregnated paper layer is patterned.

7. The method according to claim 6 , wherein the patterned first conductive material comprises a continuous meandering line selected from the group consisting of spirals, spirangles, sawtooth waves and combinations thereof.

8. The method according to claim 1 , wherein the decorative, multi-layer surfacing material further comprises an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, the enhancement layer disposed and cured between the first conductive material and one of the first and second resin impregnated layers.

9. The method according to claim 1 , wherein the decorative, multi-layer surfacing material further comprises a third resin-impregnated paper layer and a second conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus, wherein the second conductive material is disposed on a second surface of the first resin-impregnated paper layer, wherein the second surface is on a side of the first resin-impregnated paper layer opposite of the first surface, and wherein the first resin-impregnated paper layer and the third resin-impregnated paper layer are disposed in a stacked and compressed and relationship such that the second conductive material is encapsulated between the first resin-impregnated paper layer and the third resin-impregnated paper layer.

10. The method according to claim 9 , wherein the first conductive material and the second conductive material are conductively connected through the first resin-impregnated paper layer.

11. The method according to claim 9 , wherein the decorative, multi-layer surfacing material further comprises an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, the enhancement layer disposed and cured between one of the first and second conductive materials and an adjacent resin impregnated layer.

12. The method according to claim 10 , wherein the decorative, multi-layer surfacing material further comprises a third conductive material having a first terminus and a second terminus and capable of carrying an electric current, wherein the third conductive material is disposed on a first surface of the second resin-impregnated paper layer, wherein the third conductive material is in a facing relationship with the first conductive material, wherein the resin impregnating the first and second paper layers comprises a thermoset resin, and wherein an additional layer selected from the group consisting of an interposed resin-impregnated paper layer, an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, and combinations thereof, is disposed and cured between the first conductive material and the third conductive material.

13. The method according to claim 12 , wherein the first conductive material and the third conductive material are conductively connected through the additional layer.

14. The method according to claim 1 , wherein the decorative, multi-layer surfacing material further comprises a first conductive protrusion and a second conductive protrusion extending from the first terminus and second terminus of the first conductive material, respectively, to two positions along a periphery of the surfacing material and configured such that an external electrical current can be supplied to the conductive protrusion.

15. The method according to claim 1 , wherein the decorative, multi-layer surfacing material further comprises a circuit component disposed on the first surface of the first resin-impregnated paper layer and in conductive contact with the first conductive material.

16. The method according to claim 1 , wherein the decorative, multi-layer surfacing material is a high pressure laminate.

17. The method according to claim 1 , wherein the decorative, multi-layer surfacing material is disposed on a supporting substrate.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 11, 2017
From: FORMICA CORPORATION
To: THE DILLER CORPORATION
Reel/Frame 042337/0979 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 24, 2015
From: O'BRIEN, KEVIN FRANCIS; COLE, BRYCE LAMAR; KRAMER, ROBERT JACOB
To: FORMICA CORPORATION
Reel/Frame 037132/0098 →
Continuity (2)
Provisional Application 62062615 · Oct 10, 2014
Related Publication 20160104566A1 · Apr 14, 2016