WO2001051221A1

WO2001051221A1 - Flocked wall and flooring accessories

Info

Publication number: WO2001051221A1
Application number: PCT/US2001/001104
Authority: WO
Inventors: Raymond T. Warner
Original assignee: Duramax, Inc.
Priority date: 2000-01-14
Filing date: 2001-01-12
Publication date: 2001-07-19
Also published as: MXPA01009254A

Abstract

An accessory for a floor or wall (103) has a body portion (105), which has flocking material (111) covering at least part of the body portion (105), and adhesive for holding the flocking material (111) on the body portion (105).

Description

FLOCKED WALL AND FLOORING ACCESSORIES BACKGROUND OF THE INVENTION Cross-reference to Related Application

Under Title 35, United States Code § 119(e), this application claims the benefit of United States Provisional Application Serial No. 60/115,923 filed January 14, 1999. Field of the Invention

This invention relates to wall and flooring accessories, namely the surfaces of wall and flooring accessories and particularly the flocked surfaces of such accessories. Description of the Prior Art There are various wall and flooring accessories which are used for functional and cosmetic purposes and are often made from various plastics including but not limited to polyvinyl chloride ("PVC" or "vinyl"), natural and synthetic rubbers (natural rubber, IR, SBR, SSBR, BR, EPDM, etc. and blends thereof), wood and metal. The accessories include wall or cove bases which run along the base of walls adjacent to floors, and frequently extend along the walls, and interior and exterior corners, which are also disposed along the base of walls at the corners of the walls. Wall bases and comers are often used with carpets or with sheet flooring, such as vinyl tiles or rubber tiles, and can either have generally flat lower forward sections or curved lower forward sections called toes which extend over or behind the carpeting or flooring to provide a smooth, clean look. Another accessory is stringers, which are generally flat sheet material which extend along the lower part of a wall adjacent stairways, and extend along the inclined length of the stairways. The top edge of the stringer is generally several inches above the stairway tread, and runs at an angle equal to the angle of the stairway. Stringers can be made of the same type materials as are used for wall bases and corners.

Another accessory which relates to stairways, is a riser, which are the vertical parts of stairways, and which cover the vertical support or riser of the stairs. Risers can be made of the same type of materials discussed above with the other accessories. Bumpers or bumper corner guards extend along the corners of walls from at or near the floor to any height, including to the ceiling. Bumpers are provided for protecting the corner against impacts which could cause damage to the corner and to avoid the collection of dirt on the corner from people or implements contacting the corner. Bumpers could be made from the same type of materials used for the other accessories discussed above. Another accessory is cove caps, which are used for covering the edges of carpets to protect the edges from tearing and other types of damage, and for giving them a more cosmetic appearance. Cove caps generally have a base or end wall section from which extend opposing parallel walls for receiving the carpet edge between the walls so that the carpet abuts against the end wall of the cove cap. Cove caps are most often made of plastic material.

The foregoing accessories have been, until the present invention, comprised of the shaped material used for making the accessory, which are either colored by a pigment (if plastic), painted, particularly if the accessory is made from wood or metal, or left natural, as with wood. The covering for these accessories has always been smooth. In some instances, carpets extend from the floor, part way up a wall, to serve the function of cove bases, but carpets used in this fashion tend to be expensive when they serve as cove bases. All of the foregoing accessories have their smooth surfaces to protect them against damage from peoples shoes as they inadvertently walk to close to the accessory and scuff the accessory, or hit by vacuum cleaners and other cleaning devices as they are used on the floor, stairways, and on walls on which some of the accessories are provided. Although in some instances a non-smooth surface would be desirable, they are generally not used because they would be damaged or made dirty during use.

Flock has heretofore never been used with wall or flooring accessories. Flock has been used in motor vehicles because it enhances the motor vehicle's cosmetic appearance and offers various functional advantages. The functional advantages include sound dampening, insulation, surface protection of the support on which the flock is provided, and fire retardation. Flock would also be advantageous for wall end flooring accessories since it can be durable against wear, it can be washable and it can be lightfast for avoiding color change when exposed to light. Flocked accessories, as discussed above, would be particularly compatible with carpets since a flocked surface has a similar textile appearance to carpets. Summary of the Invention

An object of the present invention is to provide a surface material for wall and flooring accessories which has a fabric appearance.

Another object of the present invention is to provide a surface material for wall and flooring accessories which is compatible with carpeting.

It is yet another object of the present invention to provide a surface for wall and flooring accessories which has such advantages as being sound dampening, insulating the space which it helps enclose, and serving as a fire retardant.

It is yet a further object of the present invention to provide a surface for wall and flooring accessories which is washable.

Still another object of the present invention is to provide a surface for wall and flooring accessories whose color and length(s) can be changed to improve their cosmetic appearance and to improve their ability to harmonize with other materials with which they are used. Another object is to make unnecessary the coextrusion of a layer of rubber or vinyl on a cove or other wall or floor accessory which had been necessary to avoid "white out", which occurs when the rubber or vinyl material is bent, creating visible white areas at or near the bend.

A general object of the present invention is to provide a surface for wall and flooring accessories which is easy to apply and use, and which is economical and efficient in use.

Other objects will be apparent from the description to follow.

The foregoing objects are achieved according to the present invention by the provision of wall and flooring accessories which are covered with flock material of single or multiple colors, having good cosmetic appearance both alone and in conjunction with surfaces with other items near these accessories. The wall and flooring accessories according to the invention are made by covering the accessory with an appropriate primer and adhesive or any combination thereof, applying an electrostatic charge to the accessory and passing the electrostatically charged accessory through flock material which is drawn to the accessory by the electrostatic charge, and curing the adhesive to make a permanent bond between the flock and the adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a perspective view of a cove base according to the invention;

FIGURE 2 is a perspective view of a comer according to the invention; FIGURE 3 is a perspective view of a stringer according to the invention;

FIGURE 4 is a perspective view of a riser according to the invention;

FIGURE 5 is a perspective view of a bumper according to the invention;

FIGURE 6 is a perspective view of a cove cap according to the invention;

FIGURE 7 is a perspective view of a rollable carpet cap according to the invention;

FIGURE 8 is a perspective view of a round cove cap for capping a carpet or sheet floor, according to the invention;

FIGURE 9 is a perspective view of a carpet wall base according to the invention; FIGURE 10 is a perspective view of a cove cap according to the invention; and

FIGURE 11 is a schematic view of a system for producing flocked wall and flooring accessories. Description of the Preferred Embodiment

The present invention in its preferred form comprises accessories for walls and floors which are covered with flock to improve their cosmetic appearance, to provide sound dampening, to insulate the space which they help to contain, to protect the surface in which the flock is applied, and to retard fire. The flock should be lightfast, durable, and washable. The flock can be one color or a variety of colors, it can have different lengths and different diameters, and can have a uniform or a variety of heights for a particular accessory.

Turning first to FIG. 1, a wall or cove base 1 is shown. Wall base 1 has a vertical section 3, a toe section 5 and an intermediate section 7 wherein the vertical section is converted into the toe section. Cove base 1 has a forward or exterior section 9 facing the interior of the space which it helps define, and a back space for being applied to the wall to which it is secured. The front surface is covered with flock 11. Flock 11, applied both to cove base 1 and to other wall and flooring accessories including those described below, is made of a fiber having different diameters and lengths. One convenient diameter is .040 inches. Convenient lengths can vary from .020 inches to .060 inches or more, .040 inches being suitable. The flock can be nylon, rayon, a combination of nylon and rayon and a variety of woven or non- woven base fabrics, acrylic fiber, wool, aramid, polypropylene, polyolefin, polyethylene, PVC film and knitted fabric, cotton, polyester flock and various blends of the foregoing. The flocked surface can simulate velvet, suede, leathers, linens and flannels. In order to protect the flocked surface and to protect the flock itself, it should be washable, lightfast and durable. Flocks having these characteristics are well known in the art. Flocks are known which dampen sound, which insulate against heat, which are fire retardant, which are surface protectant, and which are durable.

FIG. 2 shows an exterior corner 10 for being attached to the corner of a wall, and could be joined with a wall or cove base. Exterior comer 10 includes upper portions 11 and 13, which meet at a corner portion 15. A toe 17 is disposed beneath upper portion 11, and a toe 19 is disposed beneath upper portion 13. Transitions 21 and 23 are disposed between upper portions 11 and 13, respectively, and toes 17 and 19. Comer 10 has an exterior or front surface 25 which is covered with flock 27 as discussed earlier.

FIG. 3 shows a stringer 30 which runs along the lower edge of a wall adjacent the end of a set of stairs 31. Stringer 30 has an upper edge 33 which is parallel to the stairs and is disposed above the stairs, and a base portion 35 which extends from the surface of the stairs to edge 33. Flock 37, as described earlier, covers the exterior surface of stringer 30.

FIG. 4 shows a set of stair risers 40 which are part of a set of stairs 42. Stairs 42 also include stair treads 43 and a landing tile 45. Risers 40 generally do not bear any load, and can be covered with flock 47 in the same manner, and with the same advantages as discussed earlier.

A bumper or bumper guard 50 is shown in FIG. 5. Bumper guard 50 protects the corner of walls, and generally does not bear any load aside from the occasional bumps which it receives. Bumper 50 includes side sections 51 and 53 which meet at a corner 55. Bumper 50 has a front surface 57 which is covered with flock 59. Flock 59 can be applied in the same colors and patterns as described earlier.

One type of cove cap is shown in FIG. 6 by numeral 60. Cove cap 60 is applied around the edges of a carpet, to protect the carpet and enhance its durability.

Cove cap 60 includes opposing, parallel walls 61 and 63. These walls extend from an end wall 65 which is perpendicular to wall 61 and 63. Wall 61 meets end wall 65 at a comer 67, and wall 63 meets end wall 65 at a comer 69. Cove cap 60 has an exterior surface 71 which is covered with flock 73 as described earlier with respect to the other wall and flooring accessories.

FIG. 7 shows another type of cove cap, i.e. a rolling cove cap 80 for extending over the edge of a carpet which extends from a floor and partially up a wall, in the manner of a wall or cove base. Rolling cove cap 80 protects the carpet and enhances its appearance, much in the manner of a cove cap. Rolling cove cap 80 includes an end wall 81, a short wall 83 for extending over the front of the carpet, and a long wall

85 for extending over the back part of the edge of a carpet. Rolling cove cap 80 has an exterior surface 87 which is covered with flock 89 as described above.

A round carpet cove cap 90 is shown in FIG. 8. Cap 90 has a base portion 91 and a hook portion 93 defining a cavity for receiving the edge of a carpet. Hook portion 93 has an exterior surface 95 to which flock 97 is adhered. Flock 97 has the same attributes discussed above. A carpet wall base 103 is shown in FIG. 9. Carpet wall base 103 has a generally flat front portion 105, and an indented portion 107 for receiving the edge of a carpet thereunder. A back section 109 would be attached to a wall. Flock 111 is dispersed over portion 105 as discussed above.

A resilient cove cap 120 is shown in FIG. 10. It has a base portion 121 and a rounded hook portion 123. Coved sheet goods, sheet goods or carpet edging would be received hook portion 103 and hook portion 123. Hook portion has an exterior surface

125 which is covered with flock as discussed above.

The manner of applying flock to the wall and flooring accessories is shown by the system 100 shown in FIG. 11. A work piece 131, which is a wall or flooring accessory as discussed earlier, is conveyed through a primer station 133 which, in the preferred embodiment, applies a solvent based primer. Work piece 131 then is transported to an adhesive applying station 135. A solvent adhesive is applied over the primer on work piece 131. The work piece then is conveyed through an electrostatic and flock station 137 where work piece 131 is electrostatically charged and flock applied. Station 137 includes a chute 139 for holding the flock, which is put in a dispersed condition by a beater or some other agitator 141, so that the flock moves through a screen 143 from which the flock "floats". The flock, shown by the numeral 145, is drawn to the electrostatically charged work piece 131 as it moves near chute 139. Flock 145 is drawn to work piece 131, where it sticks to the adhesive coated on work piece 131. The work piece, with the flock stuck on the coated adhesive, is next transported through a curing oven 147 which applies sufficient heat for a sufficient period of time, to harden the adhesive and securely bond the flock to work piece 131.

Thereafter, the cured work piece 131 is transported from curing oven 147, to another station (if necessary) where it is cut to length and ultimately packed for storage and/or shipping.

Most of the accessories are generally made from a rubber based material, which includes reinforcing agents or fillers (such as clay reinforcing agents, flame retardants, curatives and the like). They also could be made from TPE's or PVC. The accessories could be extrudates or be compression molded. Other manufacturing processes could be used as well.

Claims

What is claimed is:

1. An accessory for a floor or wall, said accessory comprising: a body portion having an exterior section observable when said accessory is in use to cover part of a wall, floor, stairway, or carpeting, and an interior section not observable when said accessory is in such use; flock material covering a least part of the exterior section of said body portion; and means for holding said flock material to the exterior section of said body portion.

2. An accessory according to claim 1 wherein said flock material is selected from the group consisting of nylon, rayon, a combination of nylon, rayon and woven or non-woven base fabrics, acrylic fiber, wool, aramid, polypropylene, polyolefin, polyethylene, PVC film and knitted fabric, cotton, polyester and blends of the components of said group.

3. An accessory according to claim 2 wherein said flock material has a diameter of approximately .040 inches.

4. An accessory according to claim 2 wherein said flock material has a length of at least .020 inches.

5. An accessory according to claim 2 wherein said flock material has a length of approximately .040 inches.

6. An accessory according to claim 2 wherein said flock material has a length from .020 inches to .060 inches.

7. An accessory according to claim 1 wherein said accessory comprises a cove base having a vertical section, a toe section and an intermediate section connecting said vertical section and said toe section.

8. An accessory according to claim 1 wherein said accessory comprises an exterior comer for attachment to a comer of a wall, said exterior comer comprising a pair of upper portions meeting at a comer portion, toe portions disposed beneath and extending from each of said upper portions, and transition portions connecting said upper portions and said toe portions.

9. An accessory according to claim 1 wherein said accessory comprises a stringer having an upper edge and a connected base portion.

10. An accessory according to claim 1 wherein said accessory comprises a stair riser.

11. An accessory according to claim 1 wherein said accessory comprises a bumper guard having a pair of side sections meeting at a comer.

12. An accessory according to claim 1 wherein said accessory comprises a cove cap, said cove cap comprising a pair of opposing, parallel walls extending from an end wall for receiving an edge of carpet between said parallel walls.

13. An accessory according to claim 1 wherein said accessory comprises a rolling cove cap, said rolling cove cap comprising an end wall and parallel opposing side walls extending from said end wall, one of said side walls being longer than the other side wall and extending further from said end wall for receiving the bottom of the edge of a carpet located between said side walls.

14. An accessory according to claim 1 wherein said accessory comprises a round carpet cove cap, said round carpet cove cap comprising a base portion and a hook portion defining a cavity for receiving the edge of a carpet.

15. An accessory according to claim 1 wherein said accessory comprises a carpet wall base, said carpet wall base having a flat face defining said exterior sections, an indented portion at one end of said flat face for receiving the edge of a carpet, and a back section for being attached to a wall and defining said interior section.

16. An accessory according to claim 1 wherein said accessory comprises a resilient cove cap, said resilient cove cap having a base portion, and a rounded hook portion extending from said base portion, said base portion having a bottom section and a first inner section defining part of said interior section, and said rounded hook portion having a second inner section defining part of said interior section and an exterior surface defining said exterior section.

17. An accessory according to claim 1 and further comprising a primer coating on said accessory.

18. A method of applying flock material to an accessory work piece for a floor, wall, stairway or carpeting, said method comprising the following steps: conveying the accessory work piece through a primer station to apply a solvent based primer; transporting the accessory work piece to an adhesive applying station to apply adhesive over said primer; conveying the accessory work piece through an electrostatic and flock material station to electrostatically charge the accessory work piece and apply flock material to the charged accessory work piece; and transporting the accessory work piece to a curing oven and applying sufficient heat over a predetermined period of time to harden the adhesive.

19. The method according to claim 18 and further including the step of transporting the accessory work piece from the curing oven to a cutting station to cut the accessory work piece to a desired length.