US 12,251,857 B2
Architectural resin panel with incorporated scrap materials
Charles H. Moore, Salt Lake City, UT (US)
Assigned to 3form, LLC, Salt Lake City, UT (US)
Filed by 3form, LLC, Salt Lake City, UT (US)
Filed on Aug. 28, 2020, as Appl. No. 17/006,093.
Claims priority of provisional application 62/972,459, filed on Feb. 10, 2020.
Prior Publication US 2021/0245400 A1, Aug. 12, 2021
Int. Cl. B29B 9/16 (2006.01); B07C 5/342 (2006.01); B29C 43/00 (2006.01); B29C 43/20 (2006.01); B29C 43/52 (2006.01); B29K 67/00 (2006.01); B29K 105/00 (2006.01); B29K 105/06 (2006.01); B29K 105/26 (2006.01); B29L 7/00 (2006.01); E04C 2/00 (2006.01); E04C 2/20 (2006.01); E04C 2/54 (2006.01)
CPC B29B 9/16 (2013.01) [B07C 5/342 (2013.01); B29C 43/006 (2013.01); B29C 43/206 (2013.01); B29C 43/52 (2013.01); E04C 2/20 (2013.01); E04C 2/54 (2013.01); B29B 2009/168 (2013.01); B29K 2067/003 (2013.01); B29K 2105/065 (2013.01); B29K 2105/251 (2013.01); B29K 2105/26 (2013.01); B29L 2007/002 (2013.01); E04C 2002/005 (2013.01)] 20 Claims
 
1. An architectural resin panel, comprising:
a plurality of plastic granules fused together to form a translucent panel core having visible borders apparent between the fused plastic granules;
wherein the plurality of plastic granules includes translucent contaminant-free granules, and contaminant granules fused to the contaminant-free granules, wherein the contaminant granules are visible between the contaminant-free granules;
wherein about 3% to about 8% of the plastic granules are contaminant granules, the contaminant granules at least partially comprise a contaminant material, and the contaminant-free granules omit the contaminant material;
wherein the contaminant granules are distributed throughout the architectural resin panel, the architectural resin panel is translucent, and the contaminate granules are visible through the panel, thereby creating a flecked aesthetic property in the architectural resin panel wherein the plurality of plastic granules comprise one or more of polyethylene terephthalate (PET), polyethylene terephthalate with glycol-modification (PETG), acrylonitrile butadiene-styrene (ABS), polyvinyl chloride (PVC), polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), polycarbonate (PC), polymethyl methacrylate (PMMA), polyolefin (UHMW or HDPE or LDPE or PP), thermoplastic polyurethane (TPU), a cellulose-based polymer, polylactic acid (PLA), or polyhydroxyalkanoate (PHA).
 
13. A translucent architectural resin panel, comprising:
a plurality of plastic granules fused together to form a panel core;
wherein:
the plurality of plastic granules includes:
substantially transparent contaminant-free granules fused together such that a border is visible between at least some of the transparent contaminant-free granules that are fused together, and
contaminant granules comprising no less than about 1% to no more than about 12% of the plastic granules,
the contaminant granules are fused to the contaminant-free granules, such that the contaminant granules are visible between the contaminant-free granules; and
the architectural resin panel is substantially devoid of visible air pockets or void defects.