Method of manufacturing a wall decoration reproducing a rocky surface.

Abstract

The invention relates to a method for manufacturing a wall decoration reproducing a rocky surface comprising a series of crevices. It comprises: Providing a first decorative element and a second decorative element, reproducing a part of the rocky surface and comprising: a material having a density less than a predetermined threshold value, a perimeter comprising a first, respectively a second, contact line representing a set of at least one first, respectively a second, crevice; the shape of the second contact line being complementary to the shape of the first contact line, Assembling the first decorative element and the second decorative element by the first contact line and the second contact line.

Description

Title of the invention: Method for manufacturing a wall decoration reproducing a rock surface.

[0001] The present invention relates to the field of interior or exterior design and decoration.

[0002] In this field, it is known to use natural or artificial stones to cover a wall, whether for aesthetic or technical purposes.

[0003] These well-known coverings are known, among others, as facing stones, stone sheets, cut stones or even slate.

[0004] They can be found commercially in various forms, ranging from individual rectangular stones to be assembled on a wall, to panels grouping together a set of these stones in order to facilitate their installation.

[0005] However, due to their rectangular shape, none of these coverings gives, once installed, a natural appearance.

[0006] To obtain a realistic rendering, it is known in the world of architecture, cinema, museums and even amusement parks to sculpt by hand different materials, notably concrete, in order to obtain the representation of a surface. Generally the desired surface is of the rocky type. However, this method is custom-made and does not allow the marketing of this representation in the form of an industrial product.

[0007] Another existing solution for obtaining such a rendering is to leave a real rock surface visible in a construction, but once again, this is not a solution that can be marketed in product form. Indeed, the density of natural stone is relatively high and its use, for example, in an apartment-type building can pose constraints to the very structure of the building.

[0008] The present invention aims to propose an alternative to these solutions by proposing an industrializable product which, once assembled on a wall, gives the impression of a natural rock surface.

[0009] In this context, the present invention relates, according to a first of its objects, to a method of manufacturing a wall decoration reproducing a rock surface comprising a set of crevices, the dimensions of said wall decoration not allowing the manufacture of said decoration in a single decorative element.

[0010] It is essentially characterized in that it comprises steps consisting of: A. Providing a first decorative element, reproducing a part of the rock surface, • said first decorative element comprising a perimeter comprising a first contact line representing a set of at least one first anfractuosity, and • said first decorative element comprising a material having a density lower than a predetermined threshold value, B. Providing a second decorative element, reproducing part of the rock surface, • said second decorative element comprising a perimeter comprising a second contact line representing a set of at least one second anfractuosity, and • said second decorative element comprising a material having a density lower than a predetermined threshold value, • the shape of the second line of contact being complementary to the shape of the first line of contact, • said second decorative element may be identical to the first decorative element, - repeat at least one of steps A or B, - assemble the first decorative element and the second decorative element by the first contact line and the second contact line.

[0011] It is also possible to provide, prior to the assembly step, at least one of the steps consisting of: • Modify the relief of the first decorative element, to generate a set of crevices, • Modify the relief of the second decorative element, to generate a set of crevices, • Modify the texture of the first decorative element, and • Modify the texture of the second decorative element.

[0012] It may be provided that the first decorative element and the second decorative element comprise a plastic-based material, in particular PVC, polystyrene or polyurethane, an expanded foam, a lightweight concrete or a lightweight resin comprising polystyrene beads; fibers, a cement, a mortar, a polymer, for example acrylic or epoxy, a biopolymer or a mixture of such materials.

[0013] For the implementation of steps A and B, steps may be provided consisting of: - Providing a model, physical or digital, of said rock surface, - Processing said model by at least one of the steps among: • Detect a set of cracks in the rock surface, • Physically or digitally modify the relief of the rock surface, to generate a set of crevices, • Modify the texture of the rock surface including a set of crevices, - Determine the position of a set of cracks in the said model, - Identify in said model a set of adjacent blocks two by two, each block being separated from an adjacent block by a crevice; - Select a set of at least one first identified block and one second identified block, and

[0014] For each selected block: - produce a decorative element corresponding to said block, according to dimensions corresponding to those of said selected block, according to a predetermined scale factor.

[0015] It may be provided that the step of providing a model of said rock surface comprises the provision of a physical model, and at least one of the steps among: • A molding of a decorative element, • a machining of a decorative element, • a cutting of a decorative element, • an additive manufacturing of a decorative element.

[0016] It may be provided that the step of providing a model of said rock surface comprises providing a digital model, said digital model comprising one of: a two-dimensional image, a three-dimensional image, a photograph, possibly retouched, a computer-generated image.

[0017] It is also possible to provide a step consisting of, for each selected block: • determining the texture of said block in the model,

[0018] the texturing step consisting of texturing said decorative element according to the texture of the selected block.

[0019] It may be provided that the first decorative element and the second decorative element comprise a material having a thermal conductivity lower than a predetermined threshold value.

[0020] Steps can be provided consisting of, for each selected block: • determining the relief of said block in the model, • structuring the surface of said corresponding decorative element according to a relief proportional to that of the selected block.

[0021] According to another of its objects, the invention relates to a wall decoration comprising a set of decorative elements manufactured according to the invention, said decorative elements being assembled two by two by a contact line representing a crevice.

[0022] Other characteristics and advantages of the present invention will appear more clearly on reading the following description given by way of illustrative and non-limiting example and made with reference to the appended figures, which may not be the scale.

[0023] [Fig.l] illustrates an embodiment of a set of blocks according to the invention,

[0024] [Fig.2] illustrates two sets of blocks of [Fig.l] adjacent along an axis ho rizontal,

[0025] [Fig.3] illustrates four sets of blocks of [Fig.l] adjacent two by two according to a horizontal axis and along a vertical axis,

[0026] [Fig.4] illustrates an embodiment of a decoration according to the invention,

[0027] [Fig.5] illustrates another embodiment of a decoration according to the invention,

[0028] [Fig.6] illustrates another embodiment of a decoration according to the invention,

[0029] [Fig.7] illustrates an image of a digital model according to the invention,

[0030] [Fig.8] illustrates the image of [Fig.7] comprising crevices whose depth has been amplified,

[0031] [Fig.9] is a photograph of a wall decoration comprising a set of blocks according to the invention,

[0032] [Fig. 10] is a photograph of another wall decoration comprising a set of blocks according to the invention.

[0033] - Detailed description -

[0034] The present invention aims to manufacture a decoration reproducing a rock surface, for example in natural stone, using a decoration of synthetic material imitating natural stone but having in particular a lower density, which facilitates the layout and exterior or interior decoration, in particular in apartments where there are architectural constraints, and thus makes it possible to have larger volumes than natural stone.

[0035] The present invention aims on the one hand to create pieces of synthetic material imitating natural stone, and on the other hand to assemble these pieces of synthetic material on a flat and generally vertical surface, typically a wall.

[0036] Due to the dimensions of a wall, it is not possible to make a decoration from a single decorative element.

[0037] It is therefore planned to manufacture pieces of synthetic material, decorative elements or blocks, which imitate the rock surface, and to assemble them so as to imitate a rock surface, for example as illustrated in [Fig.4], [Fig.5], or [Fig.6].

[0038] The materials used have a lower density than stone, which makes exterior or interior design and decoration easier, particularly in apartments where there are architectural constraints.

[0039] The present invention aims on the one hand to create pieces of synthetic material imitating the surface to be reproduced, and on the other hand to assemble these pieces of material synthesis on a flat and generally vertical surface, typically a wall.

[0040] A standard residential wall is approximately 2.50 m high. Whether for its manufacture or its transport, the dimensions of a wall decoration do not allow the manufacture of said decoration in a single decorative element.

[0041] The aim is therefore to provide a set of decorative elements which are assembled two by two to reproduce the rock surface.

[0042] The wall decoration, for example illustrated in [Fig.9] or [Fig. 10], reproduces a rock surface comprising a set of crevices, that is to say folds, cracks, hollows, irregular and sinuous depressions.

[0043] The present invention advantageously uses this set of crevices as a quasi-invisible joint between the decorative elements, as described below.

[0044] It is therefore planned to provide at least a first decorative element and a second decorative element, each reproducing a part of the rock surface.

[0045] The first decorative element comprises a perimeter which comprises a first contact line representing a set of at least one first anfractuosity.

[0046] Similarly, the second decorative element comprises a perimeter comprising a second contact line representing a set of at least one second anfractuosity.

[0047] The shape of the second contact line is complementary to the shape of the first contact line. Thus, when the first decorative element and the second decorative element are assembled by the first contact line and the second contact line, they are joined, that is to say that the edges (contact lines) of two decorative elements are brought closer to each other, the shape of the first crevice then matches the shape of the second crevice and the joint between the first decorative element and the second decorative element becomes almost invisible.

[0048] It is also possible, if necessary, to joint, that is to say to fill, in its visible part, the joint existing between the first decorative element and the second decorative element.

[0049] Advantageously, the first decorative element and the second decorative element comprise a material having a density lower than a predetermined threshold value.

[0050] For example, the first decorative element and the second decorative element comprise a plastic-based material, in particular PVC, polystyrene or polyurethane. For example, it is possible to provide expanded foam, lightweight concrete or lightweight resin, i.e. comprising polystyrene beads; or even fibers, cement, mortar, a polymer (for example acrylic or epoxy), a biopolymer or a mixture of such materials.

[0051] Thus the assembly of the decorative elements can be much easier than with natural rocks, and present an overall mass which, for example, respects architectural constraints.

[0052] Preferably, the first decorative element and the second decorative element comprise a material having a thermal conductivity lower than a predetermined threshold value. Thus, thanks to the invention, the decorative elements can also have thermal insulation qualities.

[0053] It is possible to provide for treating at least one of the first decorative element and the second decorative element.

[0054] For example, the relief of the first decorative element, or of the second decorative element, can be modified, for example to generate a set of crevices there.

[0055] The texture of the first decorative element or the second decorative element can also be modified.

[0056] We can also paint the first decorative element or the second decorative element.

[0057] It can be provided that the second decorative element is identical to the first element of decoration, for example so that the shape of the decorative element can repeat itself.

[0058] For example in [Fig.l], the set of blocks has borders which are crevices which are repeated on both sides. It is thus possible to repeat the set of blocks, therefore decorative elements, on several axes, for example as illustrated in [Fig.2] which comprises two blocks of [Fig.l] adjacent along a horizontal axis, and in [Fig.3] which comprises four blocks of [Fig.l] adjacent two by two along a horizontal axis and along a vertical axis.

[0059] To provide the first and second decorative elements, at least one of the approaches among: a so-called “physical” approach and a so-called “digital” approach can be provided.

[0060] For this purpose, a physical or digital model of the rock surface is provided. For example, the model is an initial digital file comprising an initial image; or a physical model.

[0061] The digital model may comprise a two-dimensional image, a three-dimensional image, a photograph, possibly retouched, a computer-generated image, etc.

[0062] In principle, the image can be monochrome. However, it is preferable that the image represents a relief.

[0063] The initial image file can also be presented in the form of a two-dimensional or three-dimensional file, for example from a 3D scan of a cliff or a rock face, or from a set of photographs of different views of a surface combined by photogrammetry to generate a 3D file. It is also possible to use mathematical functions for creating “procedural” textures. to generate patterns, or use textures from online 3D texture libraries. 3D file modification software can also be used, allowing you to manually "sculpt" a 3D file to give it a particular appearance, for example by bump mapping, parallax mapping, normal mapping or displacement mapping.

[0064] There is a correspondence between the brightness of the pixels in the image and the depth of the relief of the rock surface. Typically, the darker the image, the deeper the crack, and vice versa.

[0065] It is thus possible to assign to each pixel of the image a corresponding altitude or depth, which determines the “relief” of the image. Preferably, the maximum depth is standardized, that is to say it corresponds to the maximum machining depth of the decorative element corresponding to each block described below.

[0066] Knowing the relief of the image, said relief can then be machined on one face of a piece of plate of a corresponding machinable material.

[0067] The physical model may come from the molding of a decorative element, typically a reference decorative element, for example a sample.

[0068] Machining or cutting of a decorative element can also be provided.

[0069] A decorative element can also be provided by additive manufacturing.

[0070] It is then a question of treating the physical or digital model.

[0071] For this purpose, it is planned, for example, to detect in the physical or digital model a set of cracks in the rock surface.

[0072] It is also possible to physically or digitally modify the relief of the rock surface, to generate a set of crevices. In particular to generate a set of crevices which will serve as contact lines.

[0073] It is also possible to modify the texture of the rock surface comprising a set of cracks, physically or digitally; which makes it possible to modify the arrangement of the minerals constituting the rock of the surface, for example by modifying the characteristics relating to the size, the shape, the arrangement of the grains in the rock of the rock surface.

[0074] If necessary, provision is made to determine the texture of said block in the model; either prior to the modification of the texture, for example to trigger the step of modification of the texture if the determined texture does not meet certain criteria; or after the modification of the texture.

[0075] Similarly, it is possible to structure the surface of said decorative element provided according to a relief proportional to that of the block selected in the model.

[0076] Preferably, in this case, provision is made to determine the relief of the block in the model.

[0077] We can therefore modify the appearance of the rock surface by imposing an appearance on it. In the case where the rock surface to be imitated is of mineral type this aspect can be by magmatic, metamorphic, sedimentary or biogenic example, and for example a granitic, basaltic, limestone, sandstone, gypsum aspect, etc.

[0078] Once the physical or digital model has been established, it is planned to determine the position of a set of crevices.

[0079] For example, if the model is digital, the digital image can be processed directly, and if the model is physical, a digital image can be produced which can be processed in the same way.

[0080] The determination of a set of cracks can be implemented in software form, for example with descriptors based on light intensity gradients, detectors such as SIFT or SURF. It is also possible to modify or create cracks using drawing software.

[0081] The image of the model can be processed by modifying, adding, deleting, amplifying or reducing certain anfractuosities, as illustrated for example in [Fig.7] and [Fig.8].

[0082] Once the position of the crevices is determined, we can then identify in the model a set of adjacent blocks two by two, each block being separated from an adjacent block by a crevice.

[0083] It is then sufficient to select a set of at least one first identified block and one second identified block, and for each selected block to produce a decorative element corresponding to said block, according to dimensions corresponding to those of said selected block. A predetermined scale factor can be provided.

[0084] The said decorative elements can then be assembled two by two by a contact line representing a crevice. Preferably, the assembly is implemented according to the position of the blocks in the model.

[0085] It is possible to provide for identifying the blocks and marking the corresponding decorative elements to facilitate assembly.

[0086] Preferably, for the dimension of the blocks of the image, the dimensions of the smallest parallelepiped in which said block is inscribed are compared with a parallelepiped of the same shape and of predetermined dimensions. Preferably, the reference parallelepiped is a rectangle.

[0087] This reference parallelepiped with predetermined dimensions represents the dimensional limits not to be exceeded for the corresponding decorative element.

[0088] These dimensional limits may for example be linked to production constraints, transport constraints or constraints on the installation of decorative elements.

[0089] If the dimensions of the parallelepiped of a block do not fit within the dimensions of the reference parallelepiped, it is possible to review the position of the crevices and modify their position or number.

[0090] To simulate the appearance of a natural stone for each decorative element, a finishing step can be provided, comprising at least one of the following steps:

[0091] - apply at least one layer of coating to the decorative element,

[0092] - sand the decorative element,

[0093] - deburr the decorative element,

[0094] - deposit at least one protective layer, in particular a varnish, on the element of decor.

[0095] The invention is not limited to the embodiments previously described.

[0096] For example, it is possible to modify the model or the decorative elements to provide additional functionalities useful when assembling the decorative elements on a wall.

[0097] It is thus possible to create a set of at least one cavity, protrusion or flat area, to facilitate the installation of certain elements on the assembled wall decoration, such as plants, shelves or any other decorative elements, or to facilitate the installation of electrical sockets, switches, air vents or any other functional element as well as for the installation of lighting recessed into the wall.

Claims

Claims

1. Method for manufacturing a wall decoration reproducing a rock surface comprising a set of crevices, the dimensions of said wall decoration not allowing the manufacture of said decoration in a single decorative element, characterized in that the method comprises steps consisting of: A. Provide a first decorative element, reproducing part of the rock surface, • said first decorative element comprising a perimeter comprising a first contact line representing a set of at least one first anfractuosity, and • said first decorative element comprising a material having a density lower than a predetermined threshold value, B. Provide a second decorative element, reproducing part of the rock surface, • said second decorative element comprising a perimeter comprising a second contact line representing a set of at least one second anfractuosity, and • said second decorative element comprising a material having a density lower than a predetermined threshold value, • the shape of the second line of contact being complementary to the shape of the first line of contact, • said second decorative element may be identical to the first decorative element, - repeat at least one of steps A or B, - assemble the first decorative element and the second decorative element by the first contact line and the second contact line.

2. The method of claim 1, further comprising, prior to the assembly step, at least one of the steps consisting of: • Modifying the relief of the first decorative element, to generate a set of crevices therein, • Modifying the relief of the second decorative element, to generate a set of crevices therein, • Modifying the texture of the first decorative element, and • Modifying the texture of the second decorative element.

3. A method according to any one of the preceding claims, wherein the first decorative element and the second decorative element comprise a plastic-based material, in particular PVC, polystyrene or polyurethane, expanded foam, lightweight concrete or lightweight resin comprising polystyrene beads; fibers, cement, mortar, a polymer, for example acrylic or epoxy, a biopolymer or a mixture of such materials.

4. Method according to any one of the preceding claims, comprising, for the implementation of steps A and B, steps consisting in: - Providing a model, physical or digital, of said rock surface, - Processing said model by at least one of the steps among: • Detecting a set of crevices in the rock surface, • Physically or digitally modifying the relief of the rock surface, to generate a set of crevices, • Modifying the texture of the rock surface comprising a set of crevices, - Determining the position of a set of crevices in said model, - Identifying in said model a set of blocks adjacent two by two, each block being separated from an adjacent block by a crevice; - Selecting a set of at least a first identified block and a second identified block, and For each selected block: - create a decorative element corresponding to said block, according to dimensions corresponding to those of said selected block, according to a predetermined scale factor.

5. The method of claim 4, wherein the step of providing a model of said rock surface comprises providing a physical model, and at least one of the steps of: • Molding a decorative element, • Machining a decorative element, • Cutting a decorative element, • Additive manufacturing a decorative element.

6. The method of claim 4, wherein the step of providing a model of said rock surface comprises providing a digital model, said digital model comprising one of: a two-dimensional image, a three-dimensional image, a photograph, optionally retouched, a computer-generated image.

7. Method according to claim 5 or 6, further comprising a step consisting of, for each selected block: • determining the texture of said block in the model, the texture step consisting of texturing said decorative element according to the texture of the selected block.

8. A method according to any preceding claim, wherein the first decorative element and the second decorative element comprise a material having a thermal conductivity below a predetermined threshold value.

9. Method according to any one of claims 4 to 8, comprising steps consisting of, for each selected block: • determining the relief of said block in the model, • structuring the surface of said corresponding decorative element according to a relief proportional to that of the selected block.

10. Wall decoration comprising a set of decorative elements manufactured according to any one of the preceding claims, said decorative elements being assembled two by two by a contact line representing a crevice.

Images