Abstract: An integrated system and method for fabricating a countertop from a slab is disclosed. The system includes a cutting station where an apron strip of a predetermined size is cut from a slab, a translating station where the apron strip is translated and positioned along the cut edge of the slab, and a press for adhesively bonding the apron to the cut edge of the slab.

Abstract: An apparatus is disclosed for transporting panel substrates with adhesive on both sides such that the panel substrates may be used in the manufacture of decorative panels. The apparatus includes a adhesive applicator which coats a panel substrate with adhesive. The apparatus also includes a first edge support member and a second edge support member located adjacent an outlet end of the adhesive applicator such that edges of the panel substrate are respectively supported by the first edge support member and the second edge support member without interfering with the adhesive being applied to the panel substrate. The apparatus further includes a support for selectively supporting the coated panel substrate and releasing the panel substrate while only contacting edges of the panel substrate so as not to substantially interfere with the adhesive applied to the panel substrate by the adhesive applicator. A method for manufacturing a panel is also disclosed.

Abstract: An elongated wedge shaped spline can be used for joining work pieces in a dovetail joint. It can be used in joining a work piece, such as molding in a dovetailed joint. A divider track having a base support and a pair of spaced apart flanges extending at a right angle from the front surface of the base support is first affixed to a surface. The wedge shaped spline is positioned between and in abutment with the upper portion of the spaced apart flanges. A fan shaped mortise on the back surface of a work piece is positioned over the wedge shaped spline between and abutting the upper portion of the spaced apart flanges. Pressure is applied on the front surface of the work surface of the work piece for seating the work piece on the divider track, thereby forcing the wedge shaped spline between the flanges and spreading the flanges. The spread apart flanges engage the side walls of the fan shaped mortise for joining the work piece in a dovetailed joint with the divider track.

Abstract: The method for polishing stainless steel laminate press plates to produce a nondirectional, high gloss surface is achieved by initially preparing a laminate press plate for subsequent polishing and polishing the stainless steel plate in a water slurry with at least one polishing pad comprising precisely shaped pyramids containing micron graded mineral. The resulting laminate press plate is then used in the manufacture of a decorative laminate manufactured by stacking a plurality of synthetic resin impregnated paper sheets, placing the resin impregnated paper sheets between laminate press plates to produce a laminate stack and heating the laminate stack to temperatures for a time sufficient to consolidate the laminate and cure the resins.

Abstract: The invention relates to a method for producing sheets of polymeric surfacing, the sheets produced thereby, and the apparatus used to produce the sheets. The method includes providing a solid polymeric slab, and slicing the slab into sheets of surfacing. The sheets may include polymeric particles contained in a polymeric matrix. The particles may have a maximum linear dimension that is greater than the final thickness of the sheets, thereby resulting in an aesthetically pleasing “chunky” appearance. The apparatus used to slice the sheets produces a relatively smooth, uniform surface, and is capable of dramatically limiting the amount of variation in thickness within a finished sheet.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching using a process wherein the press plate and the sputtering head are moved relative to one another to provide a scanning speed sufficient to give a thermal gradient in the press plate of 50° F. or less, to provide reduced built-in stress and more delocalized heat distribution throughout the press plate.

Abstract: An installation system for installing a backsplash and countertop upon a horizontal support member. The system includes an elongated mounting bracket shaped for selective attachment to a vertical support surface. The elongated mounting bracket includes a mounting bracket retaining member. The system further includes a countertop and a backsplash, wherein the rear surface of the backsplash includes a backsplash retaining member shaped for selective attachment to the mounting bracket retaining member. In use, the elongated mounting bracket is secured to the vertical support surface adjacent the horizontal support member, the countertop is placed upon the horizontal support member with its rear edge adjacent the support surface and the mounting bracket retaining member engages the backsplash retaining member to securely retain the countertop and backsplash relative to the elongated mounting bracket, the vertical support surface and the horizontal support member.

Abstract: Multilayered dimensional laminates with improved depth appearance are provided that include a plurality of decorative layers having the same or different patterns layered so that a portion of each pattern is visible in the final dimensional laminate. Such laminate may further include a backing or core. Methods for making and using the multilayered dimensional laminates are also provided.

Abstract: Disclosed is a molding with a built-in illumination member. The illumination member may be an ordinary light or series of lights, or a repeating message board made of light emitting diodes, or a compound that glows under ultraviolet light, or a compound that glows in the dark, or the like. The molding may be the front edge molding on a worktop.

Abstract: A polymeric foam composition is provided for use as a substrate in decorative compositions having at least one decorative layer on the substrate, wherein the substrate is prepared by foaming a composition made of (i) a resin matrix of one or more polymers selected from acrylonitrile-butadiene-styrene (ABS) polymers, polycarbonates, polystyrenes, polyphenylene oxide and polyvinyl chloride polymers, preferably obtained from recycled plastics, and (ii) a filler, using one or more blowing agents. The resulting foam composition has physical and mechanical properties sufficient for its use in place of fiberboard or particle board in the preparation of various laminate based decorative products, such as laminate flooring, solid surface laminates, countertops, etc.

Abstract: 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: The process for manufacturing extruded ABS products includes recycling used ABS to produce a recycled ABS exhibiting predetermined characteristics and extruding the recycled ABS to produce an ABS product.

Abstract: The present recycling process is accomplished by first shredding used plastics to produce shredded plastics, separating metals and undesirable plastics from the shredded plastics to produce separated plastics, analyzing the material composition of the separated plastics, and blending the separated plastics to produce a desirable recycled plastic.

Abstract: A machine for processing a workpiece is provided wherein the machine has a movable continuous belt rotatably mounted around a slider bed mounted on a frame, wherein the movable belt feeds the workpiece into and through the machine and allows for the processing of the workpiece at high precision and high accuracy, particularly when the processing involves making various cutting operations in the preparation of high pressure decorative laminate surfaced moldings.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching. The preferred diborides are titanium and zirconium. The most preferred diboride is titanium. The color, gloss and surface appearance of laminate pressed with a titanium diboride coated press plate is substantially the same as laminate pressed with the press plate before coating.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching. The preferred diborides are titanium and zirconium. The most preferred diboride is titanium. The color, gloss and surface appearance of laminate pressed with a titanium diboride coated press plate is substantially the same as laminate pressed with the press plate before coating.

Abstract: A glue applicator for the installation of laminate flooring on subfloors has three laterally spaced nozzles for applying separate beads of glue onto the back of a plank of laminate flooring. Two nozzles are spaced for applying separate beads of glue along the lateral edges of a plank, the third nozzle is spaced for applying beads of glue through the center of the plank. Flanges on the sides of the glue applicator position the beads of glue on the back of a plank of laminate flooring and standoff flanges hold the nozzles above the back of the plank a sufficient distance for assuring that the glue applicator of this invention does not smear the beads.

Abstract: A stair nosing for the installation of laminate flooring on stair steps. The stair molding has an elongated, rigid base member for installation of the stair nosing on the leading edge of a stair step and an elongated, flexible tread member covering and interlocked with the rigid base member. The base member has a nose portion with a rounded front surface for defining a leading edge on a stair step and planar back surfaces that intersect at right angles. Flanges extend laterally from and on the same plane as the back surfaces of the nose portion for positioning the base portion on the tread and riser of a stair step.

Abstract: Polyvinyl acetate emulsion based adhesives can be made effective for bonding melamine formaldehyde resin treated decorative solid color and print paper to particle board. This polyvinyl acetate emulsion based adhesive is formulated with tackified polyvinyl alcohol, starch, a tackifier and a coupling agent. Stress cracking is substantially eliminated. Additionally, wrinkling and edge and corner peel resulting during the movement of sheets of melamine resin treated paper on the top and bottom surfaces of sheets of particle board through a heating and pressing zone is substantially eliminated.

Abstract: Laminate covered stair nosing is affixed with sheet metal prongs, extending at right angles from the top surface of a sheet metal fastener, on the leading edge of a stair step. The sheet metal fastener has a U shaped flange extending beyond the leading edge of the tread. The laminate covered stair nosing has a planar top surface and a planar bottom surface. Prongs on the sheet metal fastener are forced into the planar bottom surface for affixing the stair nosing on the tread. The stair nosing has a U-shaped leading edge. The U-shaped leading edge extends beyond the leading edge of the tread. The U-shaped flange on the sheet metal fastener is interlocked with a channel in the U-shaped leading edge for supporting the stair nosing on the tread. A shoulder on the stair nosing abuts with the front surface of laminate flooring on the riser for retaining laminate flooring installed over a pad on the riser of the stair step.