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The texturing, patterning and bending of a solid surface material. The end product can be achieved both through casting technologies and heat pressure processes. Controlled surface deformation can be created in a pre-manufactured flat sheet and the sheet can then be heated and bent using conventiona

The texturing, patterning and bending of a solid surface material. The end product can be achieved both through casting technologies and heat pressure processes. Controlled surface deformation can be created in a pre-manufactured flat sheet and the sheet can then be heated and bent using conventional thermoforming technology. This contrasts considerably with the conventional norm, whereby an embossed solid surface sheet, when reheated, loses its embossing.

대표청구항 ▼

1. A method of forming polymer material, said method comprising the steps of:providing polymer material having first and second surfaces; imparting a first configuration to the first surface of the polymer material; and thereafter imparting a second configuration to the second surface of the polymer

1. A method of forming polymer material, said method comprising the steps of:providing polymer material having first and second surfaces; imparting a first configuration to the first surface of the polymer material; and thereafter imparting a second configuration to the second surface of the polymer material, the second configuration comprising an altered version of the first configuration; the first and second surfaces being substantially parallel to one another prior to said step of imparting the first configuration to the first surface; the second configuration comprising a mirrored version of the first configuration with respect to a central longitudinal axis between the first and second surfaces; said step of imparting a first configuration comprising: providing a mould adapted to impart the first configuration to a surface; heating the polymer material in preparation for the mould; imparting the first configuration to the polymer material via the mould; and removing the polymer material from the mould; said step of imparting a second configuration comprising: cooling the polymer material subsequent to removal of the polymer material from the mould; thereafter rendering the second surface substantially planar; and thereafter reheating the polymer material, whereby the first surface is rendered substantially planar and the second configuration develops at the second surface. 2. The method according to claim 1, further comprising the step of bending the polymer material subsequent to imparting the second configuration to the second surface.3. The method according to claim 1, wherein the first and second configurations comprise textured configurations.4. The method according to claim 1, wherein the polymer material includes memory properties.5. The method according to claim 1, wherein a deformed configuration appears at the second surface as the first configuration is being imparted to the first surface.6. The method according to claim 1, wherein said heating step comprises heating the polymer material to at least about 275° F.7. The method according to claim 6, wherein said reheating step comprises heating the polymer material to a temperature of between about 275° F. and about 325° F.8. The method according to claim 1, wherein the polymer material comprises aluminum trihydrate and methymethacrylate.9. The method according to claim 8, wherein the polymer material comprises about 75% aluminum trihydrate and about 25% methymethacrylate.10. The method according to claim 1, wherein said step of imparting a first configuration further comprises:pressing the polymer material against the mould. 11. The method according to claim 10, wherein said step of imparting a first configuration comprises sandwiching the polymer material between the mould and a matte.12. The method according to claim 11, wherein the matte is configured for uniformly transferring a force from a press component to the polymer material while still permitting deformation of a surface of the polymer material which contacts the matte.13. The method according to claim 12, wherein a deformed configuration appears at the second surface as the first configuration is being imparted to the first surface.