Decorative panel having a digitally printed pattern and printing method therefor

Abstract

Disclosed is a method of producing a pattern for a decorative panel. The method includes applying a clear gel coat on a mold to form a clear layer. The clear layer is cured and then digitally printed with one or more inks so as to produce a pattern on the clear layer. Also disclosed is a decorative panel including a clear layer, an opaque layer and a pattern digitally printed on the clear layer, between the clear and opaque layers, such that the pattern is visible through the clear layer.

What is claimed is: 
     
         1 . A method of producing a pattern for a decorative panel, the method comprising:
 applying a first gel coat on a mold to form a first layer, the first gel coat and the first layer being clear;   curing the first layer;   digitally printing one or more inks onto the cured first layer to produce a first pattern thereon.   
     
     
         2 . The method, according to  claim 1 , in which the mold has a second pattern thereon, the first pattern printed on the first layer matching the second pattern. 
     
     
         3 . The method, according to  claim 1 , in which the first layer is cured by exposing the first layer to ultraviolet light or heat. 
     
     
         4 . The method, according to  claim 1 , further comprising curing the printed one or more inks. 
     
     
         5 . The method according to  claim 4 , in which the one or more inks are cured by exposing the inks to ultraviolet light. 
     
     
         6 . The method, according to  claim 1 , in which the clear gel coat is applied by spraying the first gel coat over substantially the entire surface of the mold. 
     
     
         7 . The method, according to  claim 1 , in which the mold includes a textured surface, the first layer being formed on the textured surface. 
     
     
         8 . The method, according to  claim 7 , in which the first pattern matches the textured surface. 
     
     
         9 . The method, according to  claim 1 , in which the mold includes a smooth surface. 
     
     
         10 . The method, according to  claim 1 , further comprising applying a second gel coat on the digitally printed first layer to form a second layer on the digitally printed first layer. 
     
     
         11 . The method, according to  claim 10 , in which the second gel coat and the second layer are opaque. 
     
     
         12 . The method, according to  claim 10 , in which the second layer is applied by spraying the second gel coat over substantially the entire surface of the digitally printed first layer. 
     
     
         13 . The method, according to  claim 10 , further comprising curing the second layer. 
     
     
         14 . The method, according to  claim 13 , in which a catalyst is mixed in the second gel coat so as to activate the curing of the second layer. 
     
     
         15 . The method, according to  claim 6 , in which the first layer has a thickness ranging from 0.001 to 0.100 inches (0.0254 mm to 2.54 mm). 
     
     
         16 . The method, according to  claim 15 , in which the first layer has a thickness ranging from 0.005 to 0.03 inches (0.127 mm to 0.761 mm). 
     
     
         17 . The method, according to  claim 16 , in which the first layer has a thickness ranging from 0.01 to 0.02 inches (0.254 mm to 0.508 mm). 
     
     
         18 . The method, according to  claim 17 , in which the first layer has a thickness of about 0.014 inches (0.356 mm). 
     
     
         19 . The method, according to  claim 12 , in which the second layer has a thickness ranging from 0 to 0.05 inches (0 mm to 1.27 mm). 
     
     
         20 . The method, according to  claim 19 , in which the second layer has a thickness ranging from 0.005 to 0.03 inches (0.127 mm to 0.761 mm). 
     
     
         21 . The method, according to  claim 20 , in which the second layer has a thickness ranging from 0.01 to 0.02 inches (0.254 mm to 0.508 mm). 
     
     
         22 . The method, according to  claim 20 , in which the second layer has a thickness of about 0.015 inches (0.381 mm). 
     
     
         23 . The method, according to  claim 13 , in which the curing of the second layer takes place for about 30 to 50 minutes. 
     
     
         24 . The method, according to  claim 23 , in which the curing of the second layer takes place for about 40 minutes. 
     
     
         25 . The method, according to  claim 2 , in which a digital printer is preprogrammed to apply the inks to match the second pattern on the mold. 
     
     
         26 . The method, according to  claim 10 , further comprising applying reinforcement material on the second layer to form a reinforcement layer on the second layer. 
     
     
         27 . The method, according to  claim 26 , in which the reinforcement material is applied by spraying the reinforcement material over substantially the entire surface of the second layer. 
     
     
         28 . A decorative panel comprising:
 a first layer defining a front of the decorative panel, the first layer being clear;   a second layer covering substantially the entire surface of the first layer;   a first pattern located between the first and second layer, the first pattern being digitally printed on one of the first layer or the second layer and being visible through the first layer.   
     
     
         29 . The decorative panel, according to  claim 28 , in which the second layer is opaque. 
     
     
         30 . The decorative panel, according to  claim 28 , further comprising a reinforcement layer covering substantially the entire surface of the second layer. 
     
     
         31 . The decorative panel, according to  claim 28 , in which the first and second layers define a textured surface. 
     
     
         32 . The decorative panel, according to  claim 28 , in which the first and second layers define a substantially smooth surface. 
     
     
         33 . The decorative panel, according to  claim 28 , in which the first pattern imitates the appearance of a natural material. 
     
     
         34 . The decorative panel, according to  claim 28 , in which the first pattern imitates the appearance of a manmade design. 
     
     
         35 . The decorative panel, according to  claim 34 , in which the manmade design is selected from a group comprising a tiled surface, brickwork and a stone wall surface.