Abstract: The invention relates to a method for fabricating a decorative laminate panel, wherein the decorative laminate panel includes a decorative laminate layer and a core. The method is achieved by forming a decorative laminate of a predetermined size, placing the decorative laminate within a die cavity, injection molding the core within the die cavity while the decorative laminate remains within the die cavity to form a decorative laminate panel and releasing the formed decorative laminate panel from the die cavity. The invention further relates to a decorative laminate panel manufactured in accordance with the method defined above and a unitary edge profile member adapted for use in the fabrication of a compound injection molded decorative laminate panel.

Abstract: An article includes a first member shaped and dimensioned for application to a rigid substrate. The first member is a decorative sheet which is adhesively bound to the substrate. The article further includes a polymeric adhesive tape securing the first member to the substrate, wherein the polymeric adhesive tape includes a heat activated, first polymeric adhesive layer which is activated at a first temperature and a heat activated, second polymeric adhesive layer which is opposite the first polymeric adhesive layer and is activated at a second temperature different from the first temperature.

Abstract: Disclosed herein is a unique torsional cutting apparatus. Two plates, referred to as a stationary and rotating plate member, are positioned and held in place next to each other using any convention means such as spring tensioned bolts. There is a zero gap between the two plate members. A hole in the general shape of the object to be cut is fashioned through the two plate members so that the object to be cut can be placed into and through the hole. The hole is tapered towards the center of the rotary torsion cutting apparatus thereby allowing ease of insertion, a more precise cut, and the elimination of burring.

Abstract: The present invention relates to a disengageable interconnecting flooring system for use in forming a temporary or permanent flooring surface on top of a support structure from individual flooring panels. The system includes two or more flooring panels comprising a top wear surface and a bottom surface for contact with the support structure. The panels have at least three edges and all edges have recesses formed therein. The system further comprises a connector having a base and a projection extending vertically from the base. The projection extending from the base is shaped to be received in a disengageable vertical connected fashion into the recesses of the panels. Preferably, the connector is comprised of a base having a projection extending the entire length thereof. In a preferred embodiment, the connector and panels further comprise means for connecting the panels in a disengageable horizontal fashion.

Abstract: The invention relates to a laminate including a decorative layer, a first resin impregnated core layer, a radiation barrier layer and a second resin impregnated core layer. The laminate prevents the penetration of radiation therethrough and maybe used in the construction of ceiling and wall panels, flooring, furniture, fixtures, cabinet and door cladding, protective screens and other objects which will effectively prevent the passage of radiation from an isolated enclosure.

Abstract: The invention relates to the bonding of a phenolic resin impregnated core and a metal sheet into a high pressure laminate. A binding layer of a styrene-maleic anhydride copolymer is positioned between the core and the metal sheet to ensure bonding of the layers when a lay-up containing the desired layers is heated and pressed.

Abstract: The invention relates to laminates including at least a first resin impregnated sheet having an electroluminescent compound dispersed therein and electrical leads coupling the electroluminescent compound to a source of electrical energy. The laminate is manufactured by applying an electroluminescent compound to a first resin impregnated sheet, applying electrical leads to the first sheet for the selectively application of electrical energy and heating and pressing the first sheet.

Abstract: A magnetically active laminate is disclosed. The magnetically active laminate is composed of a resin impregnated layer bonded to a distinct, magnetically active sheet. The laminate is especially well suited for use in the construction of erasable markerboards and cubicle panels, although many applications are possible within the scope of the present invention.

Abstract: The present invention relates to a disengageable interconnecting flooring system for use in forming a temporary or permanent flooring surface on top of a support structure from individual flooring panels. The system includes two or more flooring panels comprising a top wear surface and a bottom surface for contact with the support structure. The panels have at least three edges and all edges have recesses formed therein. The system further comprises a connector having a base and a projection extending vertically from the base. The projection extending from the base is shaped to be received in a disengageable vertical connected fashion into the recesses of the panels. Preferably, the connector is comprised of a base having a projection extending the entire length thereof. In a preferred embodiment, the connector and panels further comprise means for connecting the panels in a disengageable horizontal fashion.

Abstract: A connector for assembling and sealing laminate flooring panels which are separate from the connector, the connector comprising: a base; an extension attached to the base and having a mating member for mating with a flooring panel; and a seal attached to a member selected from the base and the extension. A method for manufacturing a connector for assembling and sealing laminate flooring panels which are separate from the connector, the method comprising: extruding a connector having a base and an extension attached to the base, wherein the extension has a mating member for mating with a flooring panel; and attaching a seal to the connector.

Abstract: A method for forming a glossy decorative laminate is disclosed. The method is achieved by stacking a decorative laminate sheet assembly having a top layer, casting a polypropylene release sheet wherein the polypropylene release sheet is processed with chill rollers treated in a manner which improves the gloss characteristics of the resulting decorative laminate, positioning the polypropylene release sheet on the top layer of the decorative laminate sheet assembly, applying heat and pressure to the decorative laminate sheet assembly and the polypropylene release sheet sufficient to bond the decorative laminate and releasably bond the polypropylene release sheet to the top layer of the decorative laminate sheet assembly, and removing the polypropylene release sheet from the top layer of the decorative laminate sheet assembly to reveal a decorative laminate exhibiting desirable gloss characteristics.

Abstract: Decorative paper with a wear resistant decorative layer is made by limiting the flow of melamine resin through the decorative paper. A partially cured melamine resin impregnated overlay is placed over non-impregnated decorative paper and cured at temperatures of about 230-310° F. (110-155° C.) and pressures of greater than about 300 psi (20 bar) and preferably about 750-1500 psi (51-102 bar) for causing melamine resin to flow from the overlay into the decorative paper and for substantially fully curing the melamine resin. Flow of the melamine resin is limited to about 10-20 and preferably about 12-17 percent by weight of the impregnated overlay. Flow of melamine resin in impregnated decorative paper is limited to about 1-3 and preferably about 1-2 percent by weight of the impregnated decorative paper.

Abstract: Disclosed is a modular worktop, and method of assembly, including a surface member, a front edge, and a backsplash, the components preferably being removably attached to each other. Each of the surface member, front edge, and backsplash may be selected from a predetermined group of decorative surfacing options, resulting in a worktop that is aesthetically pleasing to the consumer or person selecting the components. Additionally, each of the components is sized and configured so as to bring assembly and installation within the skill range of the average consumer. Because the front edge is removably attached, the front edge is changeable at the discretion of the consumer, for example, for aesthetic reasons.

Abstract: An article that is suitable for use in surface coverings, such as laminate floorings, wherein the article has at least one interlocking edge of a first profile and at least one interlocking edge of a second profile. The interlocking edges provide the ability to interlock adjacent articles without the need for an adhesive, and yet form a substantially gapless seam between the articles. The articles may be joined and unjoined from each other a plurality of times without any substantial deterioration of the interlocking edge profiles.

Abstract: A system for the fabrication of molding from stock material is disclosed. The system includes a groove cutting assembly for cutting a groove of predetermined shape and size in stock material to define a facing member and bevel member, wherein the groove is positioned between the facing member and the bevel member to define respectively opposed surfaces on the facing member and the bevel member. The system also includes an adhesive application station for applying adhesive within the groove formed by the groove cutting assembly and a folding station for bringing the opposed surfaces of the facing member and the bevel member together. The system further includes a conveyor moving the stock material through the system.

Abstract: A coupling assembly securely attaching moldings to a support surface. The coupling assembly includes a track member having first and second upwardly extending flanges defining a channel. The coupling assembly also includes a connecting member shaped and dimensioned for secure attachment within the channel defined by the upwardly extending flanges. The connecting member includes first and second expansion members which move outwardly as the connecting member is forced downwardly within the channel to securely couple the connecting member within the track member and to force the first and second upwardly extending flanges outwardly into engagement with the molding such that the molding is securely coupled to the track member. A connecting member used in conjunction with the coupling assembly and a multi-component article including the present coupling assembly are also disclosed.

Abstract: A polymeric adhesive tape including a first polymeric adhesive layer which is a heat activated film and a second polymeric adhesive layer which is a heat activated film is disclosed. The tape is designed for use in the fabrication of articles wherein the polymeric adhesive tape secures a first member to a support surface. A method for bonding adjacent sheets to a substrate is also disclosed. In accordance with the disclosed method, a substrate is prepared for application of a first sheet and a second sheet, a polymeric adhesive tape is positioned on the substrate at a position along which the seam between the first sheet and the second sheet will be located, the first sheet and the second sheet are laid on the substrate such that the seam between the first sheet and the second sheet lies along the polymeric adhesive tape, and the adhesive tape is heated along the seam to bond the substrate, adhesive tape, first laminate and second laminate.

Abstract: A polymeric adhesive tape including a first polymeric adhesive layer which is a heat activated film and a second polymeric adhesive layer which is a heat activated film is disclosed. The tape is designed for use in the fabrication of articles wherein the polymeric adhesive tape secures a first member to a support surface. A method for bonding adjacent sheets to a substrate is also disclosed. In accordance with the disclosed method, a substrate is prepared for application of a first sheet and a second sheet, a polymeric adhesive tape is positioned on the substrate at a position along which the seam between the first sheet and the second sheet will be located, the first sheet and the second sheet are laid on the substrate such that the seam between the first sheet and the second sheet lies along the polymeric adhesive tape, and the adhesive tape is heated along the seam to bond the substrate, adhesive tape, first laminate and second laminate.

Abstract: A composition and adhesive film of a thermosetting resin and a terpolymer of an &agr;-olefin, carbon monoxide and an ethylenically unsaturated carboxylic ester monomer, wherein the melt temperature of the terpolymer is less than the set temperature of the thermosetting resin. The film may be applied to a substrate to provide for an adhesive backing. The film may also be utilized to adhesively bond first and second substrates together.

Abstract: An article suitable for use in surface coverings such as laminate floorings, such articles having an upper planar decorative surface and a lower planar surface, and at least one male edge and at least one female edge. The male and female edges will interlock with corresponding female and male edges on a complimentary article. These male and female edges have profiles that provide the ability to interlock adjacent articles by approaching one article to the other at an angle, inserting the male edge into the female edge and causing the lower planar surfaces of the two articles to become coplanar, thus forming a gapless seam between the articles which can be formed, if desired, without glue and which can be, if desired, watertight.