Abstract: A method for creating a chrome-plated surface having a matte finish that typically includes: controlling a resistance of a current bridge circuit; depositing a first chromium layer on a substrate positioned in a chromium bath, wherein the first chromium layer is deposited by supplying current from a power source that is electrically connected to the substrate and to anodes positioned in the chromium bath; etching the first chromium layer by engaging a current bridge that closes the current bridge circuit; depositing a first intermediate chromium layer, wherein the first intermediate chromium layer is deposited by supplying current from the power source; etching the first intermediate chromium layer, wherein the first intermediate chromium layer is etched by engaging the current bridge; and depositing a final chromium layer, wherein the final chromium layer is deposited by supplying current from the power source.

Abstract: A method for creating a chrome-plated surface having a matte finish that typically includes: controlling a resistance of a current bridge circuit; depositing a first chromium layer on a substrate positioned in a chromium bath, wherein the first chromium layer is deposited by supplying current from a power source that is electrically connected to the substrate and to anodes positioned in the chromium bath; etching the first chromium layer by engaging a current bridge that closes the current bridge circuit; depositing a first intermediate chromium layer, wherein the first intermediate chromium layer is deposited by supplying current from the power source; etching the first intermediate chromium layer, wherein the first intermediate chromium layer is etched by engaging the current bridge; and depositing a final chromium layer, wherein the final chromium layer is deposited by supplying current from the power source.

Abstract: A system for maintaining alignment of a press plate is provided. The system comprises: a press including a press plate, the press configured for forming a laminate comprising a decorative layer and a substrate; a camera; and a processing device configured to: retrieve a laminate design file comprising a decorative design drawing layer and a texture design drawing layer, the laminate design file illustrating the decorative design drawing layer overlaid with the texture design drawing layer; following manufacture of the laminate with the press, capture an image of the laminate with the camera; compare a portion of the captured image of the laminate to a corresponding portion of the laminate design file to determine a registration quality; based on the determined registration quality, determine a misalignment of the decorative layer with the press plate; and in response to determining the misalignment, trigger an alert.

Abstract: A method for creating a chrome-plated surface having a matte finish that typically includes: controlling a resistance of a current bridge circuit; depositing a first chromium layer on a substrate positioned in a chromium bath, wherein the first chromium layer is deposited by supplying current from a power source that is electrically connected to the substrate and to anodes positioned in the chromium bath; etching the first chromium layer by engaging a current bridge that closes the current bridge circuit; depositing a first intermediate chromium layer, wherein the first intermediate chromium layer is deposited by supplying current from the power source; etching the first intermediate chromium layer, wherein the first intermediate chromium layer is etched by engaging the current bridge; and depositing a final chromium layer, wherein the final chromium layer is deposited by supplying current from the power source.

Abstract: A method for creating a chrome-plated surface having a matte finish that typically includes: controlling a resistance of a current bridge circuit; depositing a first chromium layer on a substrate positioned in a chromium bath, wherein the first chromium layer is deposited by supplying current from a power source that is electrically connected to the substrate and to anodes positioned in the chromium bath; etching the first chromium layer by engaging a current bridge that closes the current bridge circuit; depositing a first intermediate chromium layer, wherein the first intermediate chromium layer is deposited by supplying current from the power source; etching the first intermediate chromium layer, wherein the first intermediate chromium layer is etched by engaging the current bridge; and depositing a final chromium layer, wherein the final chromium layer is deposited by supplying current from the power source.

Abstract: A system for maintaining alignment of a press plate is provided. The system comprises: a press including a press plate, the press configured for forming a laminate comprising a decorative layer and a substrate; a camera; and a processing device configured to: retrieve a laminate design file comprising a decorative design drawing layer and a texture design drawing layer, the laminate design file illustrating the decorative design drawing layer overlaid with the texture design drawing layer; following manufacture of the laminate with the press, capture an image of the laminate with the camera; compare a portion of the captured image of the laminate to a corresponding portion of the laminate design file to determine a registration quality; based on the determined registration quality, determine a misalignment of the decorative layer with the press plate; and in response to determining the misalignment, trigger an alert.

Abstract: Disclosed is a method for creating a textured press plate. Initially, a mask may be applied to a surface of a press plate. This mask typically corresponds to a desired physical surface structure. Thereafter, the masked surface of the press plate is processed to obtain the desired physical surface structure. Thereafter, various techniques may be used to create differing degrees of gloss in differing portions of the surface of the press plate. For example, matting may be used to decrease the degree of gloss of a portion of the surface, and polishing may be used to increase the degree of gloss of a portion of the surface.

Abstract: Disclosed is a method for creating a textured press plate. Initially, a mask may be applied to a surface of a press plate. This mask typically corresponds to a desired physical surface structure. Thereafter, the masked surface of the press plate is processed to obtain the desired physical surface structure. Thereafter, various techniques may be used to create differing degrees of gloss in differing portions of the surface of the press plate. For example, matting may be used to decrease the degree of gloss of a portion of the surface, and polishing may be used to increase the degree of gloss of a portion of the surface.

Abstract: A method for creating a chrome-plated surface having a matte finish that typically includes: controlling a resistance of a current bridge circuit; depositing a first chromium layer on a substrate positioned in a chromium bath, wherein the first chromium layer is deposited by supplying current from a power source that is electrically connected to the substrate and to anodes positioned in the chromium bath; etching the first chromium layer by engaging a current bridge that closes the current bridge circuit; depositing a first intermediate chromium layer, wherein the first intermediate chromium layer is deposited by supplying current from the power source; etching the first intermediate chromium layer, wherein the first intermediate chromium layer is etched by engaging the current bridge; and depositing a final chromium layer, wherein the final chromium layer is deposited by supplying current from the power source.

Abstract: A method for creating a chrome-plated surface having a matte finish that typically includes: controlling a resistance of a current bridge circuit; depositing a first chromium layer on a substrate positioned in a chromium bath, wherein the first chromium layer is deposited by supplying current from a power source that is electrically connected to the substrate and to anodes positioned in the chromium bath; etching the first chromium layer by engaging a current bridge that closes the current bridge circuit; depositing a first intermediate chromium layer, wherein the first intermediate chromium layer is deposited by supplying current from the power source; etching the first intermediate chromium layer, wherein the first intermediate chromium layer is etched by engaging the current bridge; and depositing a final chromium layer, wherein the final chromium layer is deposited by supplying current from the power source.

Abstract: Systems, methods and computer program products for a virtual press plate is disclosed. A method for creating a virtual press plate includes: (a) receiving a virtual decorative layer which is an electronic representation of a physical decorative layer; (b) receiving a first virtual engraving layer having one or more first markings that correspond to a first virtual depth level; (c) receiving a second virtual engraving layer having one or more second markings that correspond to a second virtual depth level; (d) creating a virtual press plate, which is an electronic representation of a physical press plate, based at least partially on the first and second virtual engraving layers; and (e) creating a virtual pressed decorative layer by virtually pressing the virtual press plate to the virtual decorative layer.

Abstract: This invention relates to methods and apparatuses for creating a textured press plate by spreading ink over the press plate using a heater. Some embodiments provide a method that includes: (a) dispensing radiation-curable ink onto a press plate; (b) spreading the ink over the press plate by heating the ink; and (c) irradiating the ink so that the ink is at least partially cured and/or fixed, and/or such that the spreading of the ink is at least partially slowed and/or stopped. In some embodiments, the irradiating the ink occurs after the spreading the ink. In other embodiments, the ink acts to resist a chemical solution, and the method further includes etching a surface portion of the press plate by exposing the portion to a chemical solution, where the surface portion includes the ink, and where the etching the surface portion occurs after the irradiating the ink.

Abstract: This invention relates to methods and apparatuses for creating a textured press plate by spreading ink over the press plate using a heater. Some embodiments provide a method that includes: (a) dispensing radiation-curable ink onto a press plate; (b) spreading the ink over the press plate by heating the ink; and (c) irradiating the ink so that the ink is at least partially cured and/or fixed, and/or such that the spreading of the ink is at least partially slowed and/or stopped. In some embodiments, the irradiating the ink occurs after the spreading the ink. In other embodiments, the ink acts to resist a chemical solution, and the method further includes etching a surface portion of the press plate by exposing the portion to a chemical solution, where the surface portion includes the ink, and where the etching the surface portion occurs after the irradiating the ink.

Abstract: Systems, methods and computer program products for a virtual press plate is disclosed. A method for creating a virtual press plate includes: (a) receiving a virtual decorative layer which is an electronic representation of a physical decorative layer; (b) receiving a first virtual engraving layer having one or more first markings that correspond to a first virtual depth level; (c) receiving a second virtual engraving layer having one or more second markings that correspond to a second virtual depth level; (d) creating a virtual press plate, which is an electronic representation of a physical press plate, based at least partially on the first and second virtual engraving layers; and (e) creating a virtual pressed decorative layer by virtually pressing the virtual press plate to the virtual decorative layer.

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.

Abstract: Embodiments of the present invention provide systems and methods for creating textured laminate press plates that account for growth of the press plate and growth of the laminate's decorative layer. More particularly, embodiments of the present invention involve printing a two-dimensional representation of the three-dimensional surface of the proposed press plate, assuming a certain amount of expansion, onto a transparent overlay, such as a cellulose acetate sheet or a plate of glass. Embodiments of the present invention further involve positioning the overlay over an un-textured sample decorative laminate to examine the alignment of the press plate's proposed texture design with the sample laminate's decorative design.