U.S. patent application number 11/040816 was filed with the patent office on 2006-08-10 for process of making decorative flooring materials and decorative flooring material made by the process.
Invention is credited to Akiyoshi Tsukada.
Application Number | 20060174566 11/040816 |
Document ID | / |
Family ID | 36778502 |
Filed Date | 2006-08-10 |
United States Patent
Application |
20060174566 |
Kind Code |
A1 |
Tsukada; Akiyoshi |
August 10, 2006 |
Process of making decorative flooring materials and decorative
flooring material made by the process
Abstract
The present invention provides (i) a process of making
decorative flooring materials, which have elegantly designed
V-shaped grooves with curved slopes and of which the decorative
sheets hardly peel off the base materials, and (ii) a decorative
flooring material made by the process, which has elegantly designed
V-shaped grooves with curved slopes and of which the decorative
sheet hardly peels off the base material. The process of making
decorative flooring materials comprises the steps of (i) pasting a
decorative sheet 2 on a base material 1 to make a decorative
flooring material 10, (ii) cutting temporary V-shaped grooves in
the surface of the decorative flooring material 10 which are
narrower than finished V-shaped grooves with curved slopes, (iii)
positioning V-shaped pressing protrusions of a pressing die 6 above
the temporary V-shaped grooves, the slopes of each V-shaped
pressing protrusion being paraboloidal and symmetrical, (iv)
pressing the V-shaped pressing protrusions into the temporary
V-shaped grooves to form the V-shaped grooves with curved slopes 3,
the edges of the decorative sheet along the temporary V-shaped
grooves covering the curved slopes partially, (v) painting the
curved slopes in the same color as the decorative sheet 2, and (vi)
painting the entire surface of the decorative flooring material
10.
Inventors: |
Tsukada; Akiyoshi;
(Takamatsu, JP) |
Correspondence
Address: |
BEYER WEAVER & THOMAS LLP
P.O. BOX 70250
OAKLAND
CA
94612-0250
US
|
Family ID: |
36778502 |
Appl. No.: |
11/040816 |
Filed: |
January 21, 2005 |
Current U.S.
Class: |
52/384 |
Current CPC
Class: |
E04F 15/046 20130101;
B32B 2307/5825 20130101; E04F 15/102 20130101; E04F 15/02033
20130101; B44C 3/082 20130101; B32B 2250/02 20130101; E04F 15/02161
20130101; B32B 21/02 20130101; B32B 3/263 20130101; B32B 3/30
20130101; B44C 1/225 20130101; B32B 21/06 20130101; B32B 2419/04
20130101 |
Class at
Publication: |
052/384 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. A process of manufacturing decorative flooring materials
comprising the steps of: pasting a decorative sheet on a base
material to make a decorative flooring material; cutting temporary
V-shaped grooves in the surface of the decorative flooring material
which are narrower than finished V-shaped grooves with curved
slopes; positioning V-shaped pressing protrusions of a pressing die
above the temporary V-shaped grooves, the slopes of each V-shaped
pressing protrusion being paraboloidal and symmetrical; pressing
the V-shaped pressing protrusions into the temporary V-shaped
grooves to form the V-shaped grooves with curved slopes, the edges
of the decorative sheet along the temporary V-shaped grooves
covering the curved slopes partially; painting the curved slopes in
the same color as the decorative sheet; and painting the entire
surface of the decorative flooring material.
2. A decorative flooring material made by the process of claim 1
comprising a base material and a decorative sheet, a plurality of
longitudinal V-shaped grooves with curved slopes being made in the
surface of the decorative flooring material at regular intervals,
the curved slopes being paraboloidal and painted in the same color
as the decorative sheet, and then the entire surface of the
decorative flooring material being painted.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to a process of making decorative
flooring materials and a decorative flooring material made by the
process.
[0002] FIG. 7 is an illustration of a decorative flooring material
110 currently in used. The reference numeral 1 is a base material
of plywood, MDF, or the like. A decorative sheet 2 is pasted on the
base material 1 with an adhesive. V-shaped grooves 113 are made in
the decorative sheet 2 and base material 1 to (i) make the joints
between decorative flooring materials 110 inconspicuous, (ii)
absorb the variation of dimensional accuracy of decorative flooring
materials 110 and make the alignment of decorative flooring
materials 110 easy, and (iii) give the decorative flooring material
110 a good appearance. If decorative flooring materials 110 are
given V-shaped grooves 113 as narrow as 1 mm, the floor looks trim.
If decorative flooring materials 110 are given V-shaped grooves 113
as wide as 3 or 4 mm, the floor looks strong and bold. V-shaped
grooves 113 may be disposed at regular intervals or at irregular
intervals.
[0003] Because the V-shaped grooves 113 are made in the decorative
flooring material 110 with a circular or chip saw, its decorative
sheet 2 is cut. The edges of the cut decorative sheet 2 are
vulnerable to external force and liable to peel off the base
material 1.
[0004] FIG. 8 is an illustration of another decorative flooring
material 120. Shown in the left side of FIG. 8 is the decorative
flooring material 120 before V-shaped grooves 123 are made in it,
and shown in the right side of FIG. 8 is the decorative flooring
material 120 after V-shaped grooves 123 are made in it. The
V-shaped grooves 123 are made in the decorative flooring material
120 by pressing a roller or disk with small protrusions extending
circumferentially of it (Japanese Unexamined Patent Publication No.
2001-207629).
[0005] The V-shaped groove 123 is acute-angled and triangular.
Because V-shaped grooves 123 are made in the decorative flooring
material 120 by pressing a roller of disk with small protrusions
directly against the surface of the decorative flooring material
120, the V-shaped grooves 123 are liable to meander and the
decorative sheet 2 is liable to tear. If the decorative sheet 2
tears, it is liable to peel off the base material 1.
[0006] FIG. 9 is an illustration of still another decorative
flooring material 130. Shown in the left side of FIG. 9 is the
decorative flooring material 130 before V-shaped grooves 135 are
made in it, and shown in the right side of FIG. 9 is the decorative
flooring material 130 after V-shaped grooves 135 are made in it. As
shown in the left side of FIG. 9, V-shaped grooves 133 are made in
the surface of the base material 1 and a decorative sheet 2 is
pasted on the base material 1. A cut 134 is made in the decorative
sheet 2, above and along the bottom line of each V-shaped groove
133. Then, as shown in the right side of FIG. 9, the decorative
sheet 2 is heated and pressed into the V-shaped grooves 133 by a
board with V-shaped protrusions 136 to form V-shaped grooves 135
(Japanese Unexamined Patent Publication No. 1990-188205).
[0007] When the decorative sheet 2 is pressed into the V-shaped
grooves 133, the pressure is small because the V-shaped grooves 133
are formed beforehand; therefore, the decorative sheet 2 does not
sufficiently stick to the slopes of V-shaped grooves 133. The edges
of the decorative sheet 2 are liable to peel and peeled edges are
liable to catch stockings and the like.
[0008] The cuts 134 in the decorative sheet 2 are not clearly
visible; accordingly, it is difficult to position the board with
V-shaped protrusions 136 precisely on the decorative sheet 2. If
the board with V-shaped protrusions 136 is not precisely positioned
on the decorative sheet 2, grooves in an exact V shape cannot be
formed.
SUMMARY OF THE INVENTION
[0009] In view of the above problems, the object of the present
invention is to provide (i) a process of making decorative flooring
materials, which have elegantly designed V-shaped grooves with
curved slopes and of which the decorative sheets hardly peel off
the base materials, and (ii) a decorative flooring material made by
the process, which has elegantly designed V-shaped grooves with
curved slopes and of which the decorative sheet hardly peels off
the base material.
[0010] The process of making decorative flooring materials
according to the present invention comprises the steps of (i)
pasting a decorative sheet on a base material to make a decorative
flooring material, (ii) cutting temporary V-shaped grooves in the
surface of the decorative flooring material which are narrower than
finished V-shaped grooves with curved slopes, (iii) positioning
V-shaped pressing protrusions of a pressing die above the temporary
V-shaped grooves, the slopes of each V-shaped pressing protrusion
being paraboloidal and symmetrical, (iv) pressing the V-shaped
pressing protrusions into the temporary V-shaped grooves to form
the V-shaped grooves with curved slopes, the edges of the
decorative sheet along the temporary V-shaped grooves covering the
curved slopes partially, (v) painting the curved slopes in the same
color as the decorative sheet, and (vi) painting the entire surface
of the decorative flooring material.
[0011] The decorative flooring material according to the present
invention comprises a base material and a decorative sheet. A
plurality of longitudinal V-shaped grooves with curved slopes are
made in the surface of the decorative flooring material at regular
intervals. The curved slopes are paraboloidal and painted in the
same color as the decorative sheet, and then the entire surface of
the decorative flooring material is painted.
[0012] The first invention brings about the following effects.
[0013] (1) Because the pressing protrusions of the pressing die are
wider than the temporary V-shaped grooves, strong pressure is
applied to the grooves; accordingly, the close adhesion of the
decorative sheet to the base material is accomplished. The
decorative sheet does not easily peel off the base material. The
good appearance of the decorative flooring material is kept long
and the life of the decorative flooring material is long. [0014]
(2) Because the V-shaped grooves with curved slopes are formed by
pressing the temporary V-shaped grooves, the V-shaped grooves with
curved slopes are formed in exact positions. [0015] (3) Because the
V-shaped grooves with curved slopes are finished by the V-shaped
pressing protrusions of the pressing die and the slopes of each
V-shaped pressing protrusion are paraboloidal, the slopes of the
V-shaped grooves with curved slopes are paraboloidal, the grooves
assuming a soft appearance.
[0016] According to the second invention, the V-shaped grooves with
curved slopes are finished by the V-shaped pressing protrusions of
the pressing die and the slopes of each V-shaped pressing
protrusion are paraboloidal; therefore, the slopes of the V-shaped
grooves with curved slopes are paraboloidal, the grooves assuming a
soft appearance. The edges of the decorative sheet do not peel
easily. The good appearance of the decorative flooring material is
kept long and the life of the decorative flooring material is
long.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The features and advantages of the present invention will
become more clearly appreciated from the following description in
conjunction with the accompanying drawings, in which:
[0018] FIG. 1 is a perspective view of a decorative flooring
material made by a process of making decorative flooring materials
according to the present invention;
[0019] FIG. 2 is a flowchart of the process of making the
decorative flooring material of FIG. 1;
[0020] FIG. 3 (I) is a cross sectional view of the decorative
flooring material of FIG. 1 before temporary V-shaped grooves are
made in its surface; FIG. 3 (II), an illustration of the
construction of the decorative flooring material of FIG. 3 (I)
after temporary V-shaped grooves are made in its surface;
[0021] FIG. 4 (III) is an illustration of the construction of the
decorative flooring material of FIG. 3 (II) after the temporary
V-shaped grooves are reshaped;
[0022] FIG. 5 (IV) is an illustration of the construction of the
decorative flooring material of FIG. 4 (III) after the slopes of
the reshaped grooves are painted; FIG. 5 (V), an illustration of
the construction of the decorative flooring material of FIG. 5 (IV)
whose surface is entirely covered with paint;
[0023] FIG. 6 is a perspective cross sectional view of the
decorative flooring material of FIG. 1;
[0024] FIG. 7 is an illustration of a decorative flooring material
currently in use;
[0025] FIG. 8 is an illustration of another decorative flooring
material currently in use; and
[0026] FIG. 9 is an illustration of still another decorative
flooring material currently in use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] By referring to the drawing, a preferred embodiment of the
present invention will be described below.
[0028] FIG. 1 is a perspective view of a decorative flooring
material 10 made by a process of making decorative flooring
materials according to the present invention; FIG. 2, a flowchart
of the process of making the decorative flooring material 10. FIG.
3 (I) is a cross sectional view of the decorative flooring material
10 before temporary V-shaped grooves are made in its surface; FIG.
3 (II), an illustration of the construction of the decorative
flooring material 10 after temporary V-shaped grooves are made in
its surface. FIG. 4 (III) is an illustration of the construction of
the decorative flooring material 10 after the temporary V-shaped
grooves are reshaped. FIG. 5 (IV) is an illustration of the
construction of the decorative flooring material 10 after the
slopes of the reshaped grooves are painted; FIG. 5 (V), an
illustration of the construction of the decorative flooring
material 10 whose surface is entirely covered with paint. FIG. 6 is
a perspective cross sectional view of the decorative flooring
material 10.
[0029] First of all, the basic construction of the decorative
flooring material 10 will be described. As shown in FIG. 1, the
decorative flooring material 10 comprises a base material 1 and a
decorative sheet 2 which is pasted on the base material 1. The base
material 1 is plywood of five to seven veneers or MDF or a
laminated board of veneers and MDF. The decorative sheet 2 is thin
film made mainly of paper and synthetic resin and as thin as 0.01
mm to 0.5 mm. It is often as thin as 0.05 mm.
[0030] The width of the decorative flooring material 10 is about
101 cm to 303 cm. The decorative flooring material 10 has a tongue
4a on one side and a groove 4b on the other side for tongue and
groove jointing. The decorative flooring material 10, which the
decorative sheet 2 is pasted on, is processed into prescribed
dimensions.
[0031] By referring to FIGS. 2 to 5, a process of making the
decorative flooring material 10 will be described below.
[0032] As shown in FIG. 2, the process of making the decorative
flooring material 10 comprises the steps of pasting the decorative
sheet 2 on the base material 1 to make a decorative flooring
material 10 (S11), cutting the temporary V-shaped grooves in the
surface of the decorative flooring material 10 (S12), positioning
V-shaped pressing protrusions of a pressing die above the temporary
V-shaped grooves (S13), pressing the V-shaped pressing protrusions
into the temporary V-shaped grooves to form the V-shaped grooves
with curved slopes (S14), painting the curved slopes (S15), and
painting the entire surface of the decorative flooring material 10
(S16). The tongue 4a and groove 4b may be made in any step.
[0033] The steps S11 to S16 will be detailed below.
[Pasting Step S11]
[0034] As shown in FIG. 3 (I), the decorative sheet 2 is pasted on
the base material 1 with an appropriate adhesive in the step
S11.
[Groove-Cutting Step S12]
[0035] As shown in FIG. 3 (II), temporary V-shaped grooves "T" are
cut in the decorative sheet 2 and the top veneer 1a in the step
S12. It will suffice if the temporary V-shaped groove "T" is in the
shape of an approximate V. The temporary V-shaped groove "T" may
have a pointed bottom or a narrow flat bottom. The temporary
V-shaped groove "T" is narrower than the finished V-shaped groove
with curved slopes. Accordingly, when the V-shaped pressing
protrusions of a pressing die are pressed into the temporary
V-shaped grooves to form the V-shaped grooves with curved slopes,
strong force is applied to the temporary V-shaped grooves "T" to
accomplish the close adherence of the decorative sheet 2 to the
base material 1.
[Die-Positioning Step S13]
[0036] Because the temporary V-shaped groove "T" is wider than a
line made with a knife or the like, it is conspicuous. In the step
S13, a pressing die is positioned on the decorative flooring
material 10 so that the V-shaped pressing protrusions of the
pressing die will be positioned directly above the conspicuous
temporary V-shaped grooves without fail. Accordingly, when many
decorative flooring materials 10 are joined together, their
V-shaped grooves with curved slopes are aligned without fail.
[Groove-Reshaping Step S14]
[0037] FIG. 4 (III) shows a pressing die 6 in a desirable shape.
The slopes 6b and 6c of each V-shaped pressing protrusion of the
pressing die 6 are paraboloidal and symmetrical. The V-shaped
pressing protrusions are pressed into the temporary V-shaped
grooves "T" to form wider V-shaped grooves with curved slopes 3.
The edges of the decorative sheet 2 along the temporary V-shaped
grooves "T" cover the curved slopes partially.
[0038] The pressing die 6 is of a heater type. It is heated to the
temperature of 70 to 140.degree. C. The temperature is set so that
it will best fit the base material 1 and the decorative sheet
2.
[0039] By using the pressing die 6 of a heater type, V-shaped
grooves with curved slopes 3 can be made efficiently.
[Groove-Painting Step S15]
[0040] The curved slopes of V-shaped grooves 3 are painted in the
same color as the decorative sheet 2, a paint coat 4 being formed
in each groove 3 as shown in FIG. 5 (IV).
[Flooring Material-Painting Step S16]
[0041] The entire surface of the decorative flooring material 10 is
painted, paint coats 5 being formed as shown in FIG. 5 (V). A
painting apparatus with high efficiency, such as a roller coater,
can be used for color painting, under coating, intermediate
coating, and final coating because the surface, except the grooves,
of the decorative flooring material 10 is flat. Accordingly, the
painting cost is low. The surface of the decorative flooring
material 10 can be painted evenly and beautifully.
[0042] Because the V-shaped grooves 3 are finished by the V-shaped
pressing protrusions of the pressing die 6 and the slopes 6b and 6c
of each V-shaped pressing protrusion are paraboloidal, the slopes
of the V-shaped grooves 3 are paraboloidal, the grooves 3 assuming
a soft appearance. Besides, the edges of the decorative sheet 2 do
not peel easily and no peeled edges catch stockings and the
like.
[0043] The invention may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. The above embodiment is therefore to be considered in all
respects as illustrative and not restrictive, the scope of the
invention being indicated by the appended claims rather than by the
foregoing description and all changes which come within the meaning
and range of equivalency of the claims are therefore intended to be
embraced therein.
* * * * *