Systems and methods for creating textured laminates
AssigneeKings Mountain International, Inc.
InventorMartin Endert
Life of this patent
Estimating the term…
Abstract
Embodiments of the present invention provide an improved and economical system and method for viewing proposed texture designs for textured decorative laminates without having to make a press plate and a sample laminate. Embodiments of the present invention further provide systems and methods for making sample laminates and for registering a sample press plate with the laminate's decorative design when manufacturing a sample laminate. More particularly, embodiments of the present invention utilize transparent sheets, such as acetate films, in novel ways during the design of textured laminate press plates and during the registration of the press plate and the laminate's decorative layer.
Claims29
A device for use during the design and manufacture of a textured decorative laminate, the device comprising:
- an at least substantially transparent sheet having an image printed thereon, wherein the image comprises a two-dimensional representation of a three-dimensional texture design, and wherein the three-dimensional texture design is configured to be used to make a three-dimensional surface of a press plate for manufacturing the textured decorative laminate.
A system for viewing a proposed texture design for a proposed textured decorative laminate, the system comprising:
- a first sheet having a decorative image printed thereon;
- and
- a second generally transparent sheet having a two-dimensional representation of a proposed three-dimensional texture design, wherein the second generally transparent sheet is configured such that it can be overlaid over the first sheet to view the proposed texture design in conjunction with the decorative image.
A method of creating a textured decorative laminate, the method comprising:
- providing a decorative sheet having a decorative design printed thereon;
- providing a press plate having a three-dimensional surface, the three-dimensional surface comprising a plurality of depressions and/or protrusions arranged in a predetermined texture design, wherein the press plate has at least one identifiable feature;
- providing a transparent sheet having the predetermined texture design printed thereon in two-dimensions, wherein the transparent sheet has press plate positioning markings thereon showing the location of the at least one identifiable feature of the press plate relative to the predetermined texture design;
- positioning the transparent sheet over the decorative sheet such that the predetermined texture design printed on the transparent sheet aligns with the decorative design on the decorative sheet as desired;
- recording, while the transparent sheet is positioned as desired over the decorative sheet, the location, relative to the decorative sheet, of the press plate positioning markings on the transparent sheet;
- removing the transparent sheet from its position over the decorative sheet;
- providing resin on and/or around the decorative sheet;
- and
- pressing the press plate against the resin and the decorative sheet such that the at least one identifiable feature of the press plate aligns with the recorded location of the press plate positioning markings relative to the decorative sheet.
A system for registering a three-dimensional texture design with a decorative design in a laminate, the system comprising:
- a decorative layer of the laminate, the decorative layer having the decorative design printed thereon;
- a press plate having a three-dimensional surface, the three-dimensional surface having a plurality of protrusions or depressions arranged in a predetermined texture design, wherein the press plate further comprises at least one identifiable feature fixed relative to the predetermined texture design;
- a transparent sheet having a two-dimensional image of the protrusions or depressions in the predetermined texture design printed thereon, wherein the transparent sheet further has press plate positioning markings printed thereon that indicate the location of the at least one identifiable feature of the press plate relative to the predetermined texture design, and wherein the transparent sheet is configured so that it can be placed over the decorative layer such that the decorative image is visible therethrough to allow for the alignment of the two-dimensional texture design printed on the transparent sheet with the decorative design printed on the decorative layer so that, after the transparent layer is aligned with the decorative layer, the locations of the press plate positioning markings relative to the decorative layer can be recorded and available after the transparent sheet is removed from its position over the decorative layer;
- and
- a press for pressing the press plate against the decorative layer, the press configured such that the press plate can be attached to the press in such a way that the at least one identifiable feature of the press plate is aligned with the recorded location of the press plate positioning markings.
Dependencies are inferred from the claim text.