IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0716047
(2003-11-17)
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등록번호 |
US-7368031
(2008-05-06)
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발명자
/ 주소 |
- Lehr,Gregory S.
- Rubio,Alberto
- Gallegos,Salvador
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출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
1 인용 특허 :
68 |
초록
▼
The present invention provides a method for inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a core structure or core substrate. The method of the present invention includes the steps of die cutting a preselected inlay design out of a laminate sheet, die cutting a con
The present invention provides a method for inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a core structure or core substrate. The method of the present invention includes the steps of die cutting a preselected inlay design out of a laminate sheet, die cutting a congruent insert to be placed in the aperture left by the die cut design, securing the insert into the die cut design aperture, laminating with heat and pressure the laminate sheet to a core material, and conducting a finishing operation such as trimming to clean the excess laminate sheet from around the edges of the core material.
대표청구항
▼
We claim: 1. A method of inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a foam core of a sports board, comprising: cutting an aperture out of a first flexible laminate sheet; cutting a congruent insert from a second flexible laminate sheet to be placed in the apert
We claim: 1. A method of inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a foam core of a sports board, comprising: cutting an aperture out of a first flexible laminate sheet; cutting a congruent insert from a second flexible laminate sheet to be placed in the aperture of the first flexible laminate sheet; placing the congruent insert in the aperture of the first flexible laminate sheet; securing the congruent insert in place in the aperture of the first flexible laminate sheet; placing the first flexible laminate sheet with the congruent insert secured in the aperture of the first flexible laminate sheet over a foam core of a sports board; and laminating the first flexible laminate sheet and the congruent insert secured in the aperture of the first flexible laminate sheet to the foam core using heat and pressure. 2. The method of claim 1, wherein the first flexible laminate sheet and the second flexible laminate sheet are different from one another in at least one material characteristic. 3. The method of claim 2, wherein the at least one material characteristic is color. 4. The method of claim 2, wherein the at least one material characteristic is a surface property. 5. The method of claim 4, wherein the surface property is the coefficient of friction. 6. The method of inlaying of claim 1, wherein cutting the aperture out of the first flexible laminate sheet is accomplished using the same method as cutting the congruent insert out of the second flexible laminate sheet. 7. The method of inlaying of claim 6, wherein the cutting is done using a die cut operation. 8. The method of inlaying of claim 1, wherein the first and second flexible laminate sheets are made from a polymer material selected from the group consisting of polyethylene, polystyrene, polypropylene, and polyvinylchloride. 9. The method of inlaying of claim 1, wherein securing the congruent insert in the aperture of the first flexible laminate sheet includes taping the congruent insert in place. 10. The method of inlaying of claim 1, wherein laminating the first flexible laminate sheet and the congruent insert to the core structure includes feeding the core structure, the first flexible laminate sheet, and the congruent insert through a roll-press-laminating device. 11. A method of inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a foam core of a sports board, comprising: cutting an aperture out of a first flexible laminate sheet creating a first insert; cutting a congruent second insert from a second flexible laminate sheet to be placed in the aperture of the first flexible laminate sheet leaving an aperture in the second flexible laminate sheet; placing the first insert in the aperture of the second flexible laminate sheet and placing the congruent second insert in the aperture of the first flexible laminate sheet; securing the first insert in place in the aperture of the second flexible laminate sheet and securing the congruent second insert in place in the aperture of the first flexible laminate sheet; placing the first flexible laminate sheet with the second congruent insert secured in the first inlay aperture over a first foam core of a first sports board, and placing the second flexible laminate sheet with the first insert secured in the second inlay aperture over a second foam core of a second sports board; and laminating the first flexible laminate sheet and the congruent second insert to the first foam core using heat and pressure and laminating the second flexible laminate sheet and the first insert to the second foam core using heat and pressure. 12. The method of claim 11, wherein the first flexible laminate sheet and the second flexible laminate sheet are different from one another in at least one material characteristic. 13. The method of claim 12, wherein the at least one material characteristic is color. 14. The method of claim 12, wherein the at least one material characteristic is a surface property. 15. The method of claim 14, wherein the surface property is the coefficient of friction. 16. The method of inlaying of claim 11, wherein cutting the aperture out of the first flexible laminate sheet is accomplished using the same method as cutting the congruent second insert out of the second flexible laminate sheet. 17. The method of inlaying of claim 16, wherein the cutting is done using a die cut operation. 18. The method of inlaying of claim 11, wherein the first and second flexible laminate sheets are made from a polymer material selected from the group consisting of polyethylene, polystyrene, polypropylene, and polyvinylchloride. 19. A method of inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a foam core of a sports board, comprising: cutting an inlay design having at least two parts out of a first flexible laminate sheet leaving an inlay aperture; cutting a congruent insert having at least two parts from a second flexible laminate sheet leaving an inlay aperture, wherein at least one of the parts is placed in the inlay aperture of the first flexible laminate sheet; cutting a congruent insert having at least two parts from a third flexible laminate sheet leaving an inlay aperture, wherein at least one part is to be placed in the inlay aperture of the first flexible laminate sheet; aligning at least one part of the congruent insert from the second flexible laminate sheet in the inlay aperture of the first flexible laminate sheet; aligning at least one part of the congruent insert from the third flexible laminate sheet in the inlay aperture of the first flexible laminate sheet, thereby filling the inlay aperture of the first flexible laminate sheet; securing the congruent inserts from the second and third flexible laminate sheets in place in the inlay aperture of the first flexible laminate sheet; placing the first flexible laminate sheet with the congruent inserts from the second and third flexible laminate sheets secured in the inlay aperture of the first flexible laminate sheet over a foam core of a sports board; and laminating the first flexible laminate sheet with the congruent inserts secured in the inlay aperture to the foam core using heat and pressure. 20. The method of claim 19, wherein the first flexible laminate sheet, the second flexible laminate sheet and the third flexible laminate sheet are different from one another in at least one material characteristic. 21. The method of claim 20, wherein the at least one material characteristic is color. 22. The method of claim 20, wherein the at least one material characteristic is a surface property. 23. The method of claim 22, wherein the surface property is the coefficient of friction. 24. The method of inlaying of claim 19, wherein cutting the inlay design out of the first flexible laminate sheet is accomplished using the same method as cutting the congruent insert out of the second flexible laminate sheet and out of the third flexible laminate sheet. 25. The method of inlaying of claim 24, wherein the cutting is done using a die cut operation. 26. The method of inlaying of claim 19, wherein the first, second and third flexible laminate sheets are made from a polymer material selected from the group consisting of polyethylene, polystyrene, polypropylene, and polyvinylchloride. 27. The method of inlaying of claim 19, wherein securing the congruent inserts in the inlay aperture includes bonding a layer of polymer sheet over the congruent inserts; and wherein placing the first flexible laminate sheet with the congruent inserts over the foam core includes placing the first flexible laminate sheet with the congruent inserts over the foam core so that the polymer sheet is between the first flexible laminate sheet and the foam core. 28. The method of inlaying of claim 27, wherein the polymer sheet is a polyethylene sheet. 29. The method of inlaying of claim 19, wherein laminating the first flexible laminate sheet to the foam core includes feeding the foam core and the first flexible laminate sheet through a roll-press-laminating device. 30. A method of inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a foam core of a sports board, comprising: cutting a multipart inlay design out of a first flexible laminate sheet creating a first set of inserts and leaving a first inlay aperture in the first flexible laminate sheet; cutting a congruent second set of inserts from a second flexible laminate sheet leaving a second inlay aperture in the second flexible laminate sheet; cutting a congruent third set of inserts from a third flexible laminate sheet leaving a third inlay aperture in the third flexible laminate sheet; aligning at least one insert from the second set of inserts in the first inlay aperture and aligning at least one insert from the third set of inserts in the first inlay aperture; securing the at least one insert from the second set of inserts and securing the at least one insert from the third set of inserts in place in the first inlay aperture; placing the first flexible laminate sheet with the inserts secured in the first inlay aperture over a first foam core of a first sports board; and laminating the first flexible laminate sheet to the first foam core using heat and pressure. 31. The method of claim 30, further comprising: aligning at least one insert from the first set of inserts in the second inlay aperture and aligning at least one insert from the third set of inserts in the second inlay aperture; securing the at least one insert from the first set of inserts and securing the at least one insert from the third set of inserts in place in the second inlay aperture; placing the second flexible laminate sheet with the inserts secured in the second inlay aperture over a second foam core of a second snorts board; and laminating the second flexible laminate sheet to the second foam core using heat and pressure. 32. The method of claim 30, further comprising: aligning at least one insert from the first set of inserts in the third inlay aperture and aligning at least one insert from the second set of inserts in the third inlay aperture; securing the at least one insert from the first set of inserts and securing the at least one insert from the second set of inserts in place in the third inlay aperture; placing the third flexible laminate sheet with the inserts secured in the third inlay aperture over a third foam core of a third sports board; and laminating the third flexible laminate sheet to the third foam core using heat and pressure. 33. The method of claim 30, wherein the first flexible laminate sheet, the second flexible laminate sheet and the third flexible laminate sheet are different in at least one material characteristic. 34. The method of claim 33, wherein the at least one material characteristic is color. 35. The method of claim 33, wherein the at least one material characteristic is a surface property. 36. The method of claim 33, wherein the surface property is the coefficient of friction.
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