WO2008118788A1 - Improved three-dimensional interlaced decorative laminate and its fabricating method - Google Patents

Improved three-dimensional interlaced decorative laminate and its fabricating method Download PDF

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Publication number
WO2008118788A1
WO2008118788A1 PCT/US2008/057851 US2008057851W WO2008118788A1 WO 2008118788 A1 WO2008118788 A1 WO 2008118788A1 US 2008057851 W US2008057851 W US 2008057851W WO 2008118788 A1 WO2008118788 A1 WO 2008118788A1
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WO
WIPO (PCT)
Prior art keywords
interlaced
layer
strip
dimensional
directional
Prior art date
Application number
PCT/US2008/057851
Other languages
French (fr)
Inventor
Wenyi Chiu
Original Assignee
Illinois Tool Works Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Illinois Tool Works Inc. filed Critical Illinois Tool Works Inc.
Publication of WO2008118788A1 publication Critical patent/WO2008118788A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/10Fibres of continuous length
    • B32B2305/18Fabrics, textiles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00Animal or vegetable based
    • B32B2317/12Paper, e.g. cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives

Definitions

  • the present invention relates to an indoor decorating material with three-dimensional interlaced surface layer and its fabricating method.
  • Surface decorating materials are the necessary materials that people use to decorate their indoor environment. At present, most surface decorating materials including wallpaper, lacquer, paint, and fire-resistant board, etc. are used for plane decoration, but lack three-dimensional effects. It is possible to build, on the construction site, a three-dimensional model on a plane surface using separate materials, but this has some disadvantages and inconveniences in construction.
  • plant fibre sheet such as thin wood sheet
  • interlacing materials such plant fibre sheet and thin wood sheet
  • a piece of paper is adhered on the undersurface of the strips before there are interlaced as a three dimensional surface sheet.
  • a piece of paper is then adhered to the undersurface of the three dimensional surface sheet by glue to form a three dimensional decoration sheet.
  • a substrate (such as a laminate) is adhered at the undersurface of the three dimensional surface sheet to form the existing three-dimensional interlaced decorative laminate.
  • the adhesive strength between the glue and the paper decreases and the paper becomes more brittle after the glue dries.
  • a plan sheet (or interlacing strips) may break irregularly and unexpectedly along the cutting edge when the plane sheet (or the interlacing strips) is being cut into desired shapes.
  • a plane sheet may break when it is fold as a roll due to the brittleness of the piece of paper on the undersurface of the interlaced plane sheet, which may increase the difficulty to carry, transport and install.
  • the glue functioning as a connecting and fixing medium between the paper and substrate will be further absorbed by the paper, which may cause reducing adhesive strength even causing separation and detachment of the interlaced plane sheet from the substrate.
  • the first technical problem to be solved in the present invention is to provide the structure of a three dimensional decoration sheet, which ensures that no break occurs when it is being cut.
  • the second technical problem to be solved in the present invention is to provide the structure of a three dimensional decoration sheet, which ensures that the product has the strength of being rolled without breaking.
  • the third technical problem to be solved in the present invention is to provide the structure of a three-dimensional interlaced decorative laminate, where the adhesive glue is absorbed in the process of manufacturing and the adhesive glue is absorbed slowly during everyday use, to ensure that the layers can adhere and fix to each other.
  • the present invention provides a three-dimensional decoration sheet, comprising: a first directional interlaced strip material (1) and a first fibre cloth strip layer (4), wherein, the uppersurface of the first fibre cloth strip layer (4) adheres to the undersurface of the first directional interlaced strip material (1), to form a first directional interlaced strip with the undersurface of the first fibre cloth strip layer (4); a second directional interlaced strip material (2) and a second fibre cloth strip layer (4'), wherein, the uppersurface of the second fibre cloth strip layer (4') adheres to the undersurface of the second directional interlaced strip material (2), to form a second directional interlaced strip with the undersurface of the second or fibre cloth strip layer (4'); the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of
  • the present invention forms a three-dimensional decoration sheet by further adding the following components into the above-mentioned three-dimensional decoration sheet as follows: a glue-coated paper layer (7), which adheres to the glue film layer (6); a substrate (3), which adheres, through heat and/or pressure, to the three dimensional decoration sheet having the glue-coated paper layer (7), to form a decorative laminate with three-dimensional interlaced surface layer.
  • the present invention provides another type of a three dimensional decoration sheet, comprising: a first directional interlaced strip; a second directional interlaced strip; the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet.
  • the present invention also provides the corresponding fabricating methods for fabricating the decorative laminate with three-dimensional interlaced surface layer, and the corresponding fabricating method for fabricating a three dimensional decoration sheet.
  • the decorative laminate provided by the present invention with three-dimensional interlaced surface layer and its sheet working as a surface with effect of third dimension, is possessed with the advantages, such as easiness to fabricate, high quality, no occurrence of detachment between layers, high intensity, and easiness to roll, take, and transport, etc.
  • Fig. IA shows a sheet 12A used to fabricate the surface of a three-dimensional interlaced decorative laminate.
  • Fig. IB shows that a fibre cloth 13 A is adhered to the back side of the sheet 12A by glue to form a surface sheet 14B.
  • Fig. 1C shows the case where a surface sheet 14B is cut into interlacing strips 15C.
  • Fig. ID shows the case where the interlacing strips 15C are interlaced in a longitudinal-transversal way, in both first direction and second direction, to form a interlaced surface sheet 16D which is used as a three-dimensional interlaced surface layer;
  • Fig. 2A shows the case where there is a fibre cloth 22A on the undersurface of the interlaced surface sheet 16D.
  • Fig. 2B shows the case where fibre cloth 22A adheres to the undersurface of interlaced surface sheet 16D by glue to form a three dimensional decoration sheet 23B.
  • Fig. 3 A is the first embodiment of the present invention.
  • Fig. 3 B is the second embodiment of the present invention.
  • Fig.4A is the schematic sectional view of the three-dimensional interlaced decorative laminate according to the first embodiment (shown in Fig. 3A) of the present invention.
  • Fig. 4B is the schematic sectional view of the three-dimensional interlaced decorative laminate according to the second embodiment (shown in Fig. 3B) of the present invention.
  • Fig. 5A is the three dimensional surface sheet according to a third embodiment of the present invention.
  • Fig. 5 B is a sectional view of three dimensional surface sheet in Fig. 5 A showing the first and second directional strips according to a third embodiment of the present invention.
  • Fig. 5 C is a sectional view showing the three dimensional surface sheet in Fig. 5A is adhered on to a fibre cloth to form a three dimensional decoration sheet according to a third embodiment of the present invention.
  • Fig. 5D is a sectional view showing the three dimensional decoration sheet in
  • Fig. 5C is adhered onto a substrate to form a three-dimensional interlaced decorative laminate according to a third embodiment of the present invention.
  • Fig. IA shows a sheet 12A used to fabricate the surface of a three-dimensional interlaced decorative laminate.
  • the material of sheet 12A can be plant fibre (such as bamboo, wood, cotton and linen), metal, or other synthetic materials (such as plastic and emulational synthetic materials).
  • a sheet of fibre cloth 13 A is disposed on the undersurface of sheet 12 A.
  • the material of sheet 13A can be non- woven cloth, polyester cloth or plant (including cotton) fibre cloth.
  • the uppersurface of fibre cloth 13A is coated with glue that is selected to match with the material of sheet 12A so that sheet 12A and sheet 13A can adhere to each other strongly.
  • the present invention allows variety of materials, such as plant fibre (including bamboo, wood, cotton and linen), metal, and other synthetic materials (including plastic and emulational synthetic materials), to be used as the materials of sheet 12 A.
  • sheet 13 A adheres to undersurface of sheet 12Aby glue to form a surface sheet 14B.
  • the undersurface of surface sheet 14B i.e. the undersurface of sheet 13A
  • a layer of glue that is selected to have the performance of drying easily, but is still having proper viscidity after drying so that an article adhering to the undersurface of the surface sheet 14B can be easily detached and re-adhered easily to the undersurface of surface sheet again with enough degree of firmness after re-adhering.
  • Fig. 1C surface sheet
  • first directional interlaced strip material 1 and the first fibre cloth strip layer 4 are shown as first directional interlaced strip material 1 and the first fibre cloth strip layer 4, respectively, or are shown as second directional interlaced strip material 2 and the second fibre cloth strip layer 4' respectively (see Fig. 4A and Fig. 4B).
  • interlacing strips 15C are interlaced in two directions (a first direction and a second direction) to form a three dimensional surface sheet 16D.
  • first and the second directions may be intersected orthogonal with the right angle or with non-right angles.
  • the glue coated on the undersurface of sheet 13A has a property to be easily dried and still having proper viscidity, so that an article may be conveniently taken off from the undersurface on which the article was adhered thereon, and the taken-off article may then be conveniently adhered onto the undersurface again. Therefore, in interlacing process, the interlacing strips 15C may be conveniently moved to desired positions in two interlacing directions.
  • the interlacing strips 15C may be firmly and evenly bonded together to form a three dimensional surface sheet 16D by applying a pressing force.
  • the surface sheet 16D has a three dimensional appearance on its top surface 17D.
  • a fibre cloth 22A is disposed on the undersurface of the interlaced surface sheet 16D (Note: fibre cloth 22A is shown as fibre cloth layer 5 in Fig.4A and 4B). The uppersurface of the fibre cloth 22A is coated with glue.
  • Fig. 2B the fibre cloth 22A is adhered to the undersurface of the three-dimensional interlaced surface sheet 16D to form a three dimensional decoration sheet 23B that has an uneven uppersurface 17D and a smooth undersurface.
  • the smooth undersurface of the three dimensional decoration sheet 23B is helpful to adhere it to the surface of other articles.
  • the three dimensional decoration sheet 23B itself can be used as decoration materials to be adhered onto the surfaces of an article.
  • Fig. 3 A is a first embodiment of the three-dimensional interlaced decorative laminate in the present invention. As shown in Fig.
  • a sheet of paper 32 A with a solid glue film layer being coated on its undersurface (glue-coated paper layer 32A") (Note: the corresponding part to the glue-coated paper layer 7 shown in Fig. 4A).
  • a substrate 33 A Disposed under the glue-coated paper layer 32A is a substrate 33 A, which can be made of laminate, plastic and metal, etc.
  • the solid glue film layer on the undersurface of the glue-coated paper layer 32A presents strong viscidity through heating and pressure. There is no viscid material on the uppersurface of the glue-coated paper layer 32A.
  • the undersurface of the three dimensional decoration sheet 23 B is coated with a glue film layer which can adhere the three dimensional decoration sheet 23B onto the uppersurface of the glue-coated paper layer 32A.
  • the three dimensional decoration sheet 23B, the glue-coated paper layer 32A and the substrate 33A are arranged as a stack into a heating-press machine (not shown).
  • the stack is heated and pressed within the heating-press machine.
  • the glue film layer adheres the undersurface of the three dimensional decoration sheet 23B onto the uppersurface of the glue-coated paper layer 32 A.
  • the solid glue film layer on the undersurface of the glue-coated paper layer 32 A melts, thus adhering undersurface of the glue-coated paper layer 32A onto to the substrate 33A.
  • Fig. 3 B is the second embodiment of the three-dimensional interlaced decorative laminate in the present invention.
  • the substrate 33B can be wood board (such as core board, clip board, medium density board, and three-ply board, etc.), plastic board, metal board or other synthetic material board.
  • the three dimensional decoration sheet 23 B (which is coated with a glue film layer on its undersurface) and the substrate 33B are arranged as a stack into a cold-press machine (not shown) and adhere with each other through a cold pressure process.
  • the three dimensional decoration sheet 23B and the substrate 33B are arranged into a heating-press machine (not shown) as a stack and adhere with each other through heat and pressure. Because it is easier to adhere the wood substrate 33B onto the undersurface of the three dimensional decoration sheet 23 B, the glue-coated paper layer 32A in the first embodiment can be left out and the glue film layer on the undersurface of the three dimensional decoration sheet 23B needs not to be selected as strictly as in the embodiment shown in Fig. 3A. However, if a substrate 33B were made of plastic board or metal board, the glue film layer needs to be selected strictly.
  • Fig. 4A is the sectional view of the three-dimensional interlaced decorative laminate according to the first embodiment (shown in Fig. 3A) of the present invention.
  • the sectional view of the three-dimensional interlaced decorative laminate shows a first directional interlaced strip material 1 and the second directional interlaced strip material 2.
  • the first directional fibre cloth strip layer 4 and the second directional fibre cloth strip layer 4' adhere to the undersurfaces of the first directional interlaced strip material 1 and the back side of the second directional interlaced strip material 2, respectively.
  • the fibre cloth layer 5 adheres to the undersurface of interlaced surface sheet 16D which is interlaced by the first directional interlaced strip 1 and the second directional interlaced strip 2 (see reference 15C in Fig. 1C) and has an interlaced uppersurface with three dimensional effect.
  • Fig. 4B is the sectional view of the three-dimensional interlaced decorative laminate according to the second embodiment (shown in Fig. 3B) of the present invention.
  • the sectional view of the three-dimensional interlaced decorative laminate shows the first directional interlaced strip material 1 and the second directional interlaced strip material 2.
  • the first directional fibre cloth strip layer 4 and the second directional fibre cloth strip layer 4' adhere to the undersurface of the first directional interlaced strip material 1 and the undersurface of the second directional interlaced strip material 2, respectively.
  • the fibre cloth layer 5 adheres to the undersurface of interlaced surface sheet 16D which is interlaced by the first directional interlaced strip 1 and the second directional interlaced strip 2 (see reference 15C in Fig. 1C) and has an interlaced uppersurface with three dimensional effect. Underneath the fibre cloth layer 5, there is a substrate 3.
  • Figs. 5A-5D is a third embodiment of the three-dimensional interlaced decorative laminate in the present invention.
  • three dimensional surface sheet 16D' is interlaced by a plurality of first directional strips and a plurality of second directional strips.
  • the materials for the first and second directional strips are formed by cutting the same material sheet used in the first and second embodiments (i.e., sheet 12A as shown Fig. IA).
  • sheet 12A as shown Fig. IA.
  • no layers are disposed on the undersurface of the sheet 12A when the sheet is cut into strips; there are no layers under the first and second directional strips when they are being interlaced into the three dimensional surface sheet 16D'.
  • Fig. 5B is a sectional view of three dimensional surface sheet 16D' showing the first and second directional strips.
  • Fig. 5C is a sectional view of three dimensional surface sheet 16D' showing the three dimensional surface sheet 16D' is adhered on to a fibre cloth 5 to form a three dimensional decoration sheet 23B'. It should be noted that the three dimensional decoration sheet 23 B' itself can be used as decoration materials to be adhered onto the surfaces of an article.
  • Fig. 5D is a sectional view of three dimensional surface sheet 16D' showing the three dimensional decoration sheet 23B' is adhered onto a substrate 3 to form the three-dimensional interlaced decorative laminate.
  • the fibre cloth mentioned in the present invention is preferably to be non-woven cloth made of a chemical material such as polyester.
  • This type of non- woven cloth does not absorb glue, and therefore can avoid the loss of the glue in the process of heat and/or pressure, and can avoid the occurrence of the circumstance where the glue is absorbed slowly during the use.
  • this type of non- woven cloth is higher in tenacity than the paper.

Abstract

The present invention discloses an improved three-dimensional interlaced decorative laminate and its fabricating method, wherein the undersurface of interlacing strip materials adheres to the uppersurface of fibre cloth strip layer with its undersurface coated with a layer of glue, to form a first and second directional interlacing strips The first directional interlaced strip and the second directional interlaced strip interweave to form a three dimensional interlaced surface sheet layer. The uppersurface of the fibre cloth layer adheres to the undersurface of a three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet. In addition, a substrate adheres to the three dimensional decoration sheet having the glue-coated paper layer to form a decorative laminate with three-dimensional interlaced surface layer.

Description

IMPROVED THREE-DIMENSIONAL INTERLACED DECORATIVE LAMINATE AND ITS FABRICATING METHOD
FIELD OFTHE INVENTION The present invention relates to an indoor decorating material with three-dimensional interlaced surface layer and its fabricating method.
BACKGROUND OFTHE INVENTION
Surface decorating materials are the necessary materials that people use to decorate their indoor environment. At present, most surface decorating materials including wallpaper, lacquer, paint, and fire-resistant board, etc. are used for plane decoration, but lack three-dimensional effects. It is possible to build, on the construction site, a three-dimensional model on a plane surface using separate materials, but this has some disadvantages and inconveniences in construction. There is existing three-dimensional interlaced decorative laminate that uses plant fibre sheet (such as thin wood sheet) as interlacing materials. To form the three-dimensional interlaced decorative laminate, interlacing materials (such plant fibre sheet and thin wood sheet) are cut into strips, which are further interlaced as a three dimensional surface sheet. Optionally, a piece of paper is adhered on the undersurface of the strips before there are interlaced as a three dimensional surface sheet. A piece of paper is then adhered to the undersurface of the three dimensional surface sheet by glue to form a three dimensional decoration sheet. Finally, a substrate (such as a laminate) is adhered at the undersurface of the three dimensional surface sheet to form the existing three-dimensional interlaced decorative laminate. However, there are some disadvantages in this type of three-dimensional interlaced decorative laminate. First, the adhesive strength between the glue and the paper decreases and the paper becomes more brittle after the glue dries. Second, a plan sheet (or interlacing strips) may break irregularly and unexpectedly along the cutting edge when the plane sheet (or the interlacing strips) is being cut into desired shapes. Thirdly, a plane sheet may break when it is fold as a roll due to the brittleness of the piece of paper on the undersurface of the interlaced plane sheet, which may increase the difficulty to carry, transport and install.
Furthermore, after a period of time of use, the glue functioning as a connecting and fixing medium between the paper and substrate will be further absorbed by the paper, which may cause reducing adhesive strength even causing separation and detachment of the interlaced plane sheet from the substrate.
SUMMARY OF THE INVENTION
Among the technical problems to be solved, the first technical problem to be solved in the present invention is to provide the structure of a three dimensional decoration sheet, which ensures that no break occurs when it is being cut.
The second technical problem to be solved in the present invention is to provide the structure of a three dimensional decoration sheet, which ensures that the product has the strength of being rolled without breaking. The third technical problem to be solved in the present invention is to provide the structure of a three-dimensional interlaced decorative laminate, where the adhesive glue is absorbed in the process of manufacturing and the adhesive glue is absorbed slowly during everyday use, to ensure that the layers can adhere and fix to each other. hi order to solve the technical problems mentioned above, the present invention provides a three-dimensional decoration sheet, comprising: a first directional interlaced strip material (1) and a first fibre cloth strip layer (4), wherein, the uppersurface of the first fibre cloth strip layer (4) adheres to the undersurface of the first directional interlaced strip material (1), to form a first directional interlaced strip with the undersurface of the first fibre cloth strip layer (4); a second directional interlaced strip material (2) and a second fibre cloth strip layer (4'), wherein, the uppersurface of the second fibre cloth strip layer (4') adheres to the undersurface of the second directional interlaced strip material (2), to form a second directional interlaced strip with the undersurface of the second or fibre cloth strip layer (4'); the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet with the undersurface of the fibre cloth layer (5) coated with a glue film layer (6).
In order to solve the technical problems mentioned above, the present invention forms a three-dimensional decoration sheet by further adding the following components into the above-mentioned three-dimensional decoration sheet as follows: a glue-coated paper layer (7), which adheres to the glue film layer (6); a substrate (3), which adheres, through heat and/or pressure, to the three dimensional decoration sheet having the glue-coated paper layer (7), to form a decorative laminate with three-dimensional interlaced surface layer.
In order to solve the technical problems mentioned above, the present invention provides another type of a three dimensional decoration sheet, comprising: a first directional interlaced strip; a second directional interlaced strip; the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet.
The present invention also provides the corresponding fabricating methods for fabricating the decorative laminate with three-dimensional interlaced surface layer, and the corresponding fabricating method for fabricating a three dimensional decoration sheet. Compared to the existing decorative laminate with three-dimensional interlaced surface layer, the decorative laminate provided by the present invention, with three-dimensional interlaced surface layer and its sheet working as a surface with effect of third dimension, is possessed with the advantages, such as easiness to fabricate, high quality, no occurrence of detachment between layers, high intensity, and easiness to roll, take, and transport, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
By the detailed description of the present invention with reference to the drawings, the persons skilled in this field can understand clearly the purpose, the technical problems to be solved, the technical features, and other content, of the present invention.
Fig. IA shows a sheet 12A used to fabricate the surface of a three-dimensional interlaced decorative laminate. Fig. IB shows that a fibre cloth 13 A is adhered to the back side of the sheet 12A by glue to form a surface sheet 14B.
Fig. 1C shows the case where a surface sheet 14B is cut into interlacing strips 15C.
Fig. ID shows the case where the interlacing strips 15C are interlaced in a longitudinal-transversal way, in both first direction and second direction, to form a interlaced surface sheet 16D which is used as a three-dimensional interlaced surface layer;
Fig. 2A shows the case where there is a fibre cloth 22A on the undersurface of the interlaced surface sheet 16D. Fig. 2B shows the case where fibre cloth 22A adheres to the undersurface of interlaced surface sheet 16D by glue to form a three dimensional decoration sheet 23B.
Fig. 3 A is the first embodiment of the present invention. Fig. 3 B is the second embodiment of the present invention. Fig.4A is the schematic sectional view of the three-dimensional interlaced decorative laminate according to the first embodiment (shown in Fig. 3A) of the present invention.
Fig. 4B is the schematic sectional view of the three-dimensional interlaced decorative laminate according to the second embodiment (shown in Fig. 3B) of the present invention.
Fig. 5A is the three dimensional surface sheet according to a third embodiment of the present invention.
Fig. 5 B is a sectional view of three dimensional surface sheet in Fig. 5 A showing the first and second directional strips according to a third embodiment of the present invention.
Fig. 5 C is a sectional view showing the three dimensional surface sheet in Fig. 5A is adhered on to a fibre cloth to form a three dimensional decoration sheet according to a third embodiment of the present invention. Fig. 5D is a sectional view showing the three dimensional decoration sheet in
Fig. 5C is adhered onto a substrate to form a three-dimensional interlaced decorative laminate according to a third embodiment of the present invention.
DETAILED DESCRIPTION OFTHE PREFERRED EMBODIMENTS Fig. IA shows a sheet 12A used to fabricate the surface of a three-dimensional interlaced decorative laminate. The material of sheet 12A can be plant fibre (such as bamboo, wood, cotton and linen), metal, or other synthetic materials (such as plastic and emulational synthetic materials). A sheet of fibre cloth 13 A is disposed on the undersurface of sheet 12 A. The material of sheet 13A can be non- woven cloth, polyester cloth or plant (including cotton) fibre cloth. The uppersurface of fibre cloth 13A is coated with glue that is selected to match with the material of sheet 12A so that sheet 12A and sheet 13A can adhere to each other strongly. Because a sheet of fibre cloth 13A adheres onto to the undersurface of sheet 12 A, the present invention allows variety of materials, such as plant fibre (including bamboo, wood, cotton and linen), metal, and other synthetic materials (including plastic and emulational synthetic materials), to be used as the materials of sheet 12 A.
As shown in Fig. IB, sheet 13 A adheres to undersurface of sheet 12Aby glue to form a surface sheet 14B. The undersurface of surface sheet 14B (i.e. the undersurface of sheet 13A) is coated with a layer of glue that is selected to have the performance of drying easily, but is still having proper viscidity after drying so that an article adhering to the undersurface of the surface sheet 14B can be easily detached and re-adhered easily to the undersurface of surface sheet again with enough degree of firmness after re-adhering. As shown in Fig. 1C, surface sheet
14B is cut into strips to form the interlacing strips 15C that can be used to interlace a three dimensional surface sheet 16D as shown in Fig. ID .
It should be noted that, after being interlaced, the two layers of materials on a strip 15C are shown as first directional interlaced strip material 1 and the first fibre cloth strip layer 4, respectively, or are shown as second directional interlaced strip material 2 and the second fibre cloth strip layer 4' respectively (see Fig. 4A and Fig. 4B).
As shown in Fig. ID, interlacing strips 15C are interlaced in two directions (a first direction and a second direction) to form a three dimensional surface sheet 16D. It should be noted that the first and the second directions may be intersected orthogonal with the right angle or with non-right angles. Because the glue coated on the undersurface of sheet 13A has a property to be easily dried and still having proper viscidity, so that an article may be conveniently taken off from the undersurface on which the article was adhered thereon, and the taken-off article may then be conveniently adhered onto the undersurface again. Therefore, in interlacing process, the interlacing strips 15C may be conveniently moved to desired positions in two interlacing directions. After moving to the desired positions along two interlacing directions, the interlacing strips 15C may be firmly and evenly bonded together to form a three dimensional surface sheet 16D by applying a pressing force. As shown in Figure ID, the surface sheet 16D has a three dimensional appearance on its top surface 17D. As shown in Fig. 2A, a fibre cloth 22A is disposed on the undersurface of the interlaced surface sheet 16D (Note: fibre cloth 22A is shown as fibre cloth layer 5 in Fig.4A and 4B). The uppersurface of the fibre cloth 22A is coated with glue.
As shown in Fig. 2B, the fibre cloth 22A is adhered to the undersurface of the three-dimensional interlaced surface sheet 16D to form a three dimensional decoration sheet 23B that has an uneven uppersurface 17D and a smooth undersurface. The smooth undersurface of the three dimensional decoration sheet 23B is helpful to adhere it to the surface of other articles. It should be noted that the three dimensional decoration sheet 23B itself can be used as decoration materials to be adhered onto the surfaces of an article. Fig. 3 A is a first embodiment of the three-dimensional interlaced decorative laminate in the present invention. As shown in Fig. 3 A, disposed under the three dimensional decoration sheet 23B is a sheet of paper 32 A with a solid glue film layer being coated on its undersurface ("glue-coated paper layer 32A") (Note: the corresponding part to the glue-coated paper layer 7 shown in Fig. 4A). Disposed under the glue-coated paper layer 32A is a substrate 33 A, which can be made of laminate, plastic and metal, etc. The solid glue film layer on the undersurface of the glue-coated paper layer 32A presents strong viscidity through heating and pressure. There is no viscid material on the uppersurface of the glue-coated paper layer 32A. But the undersurface of the three dimensional decoration sheet 23 B is coated with a glue film layer which can adhere the three dimensional decoration sheet 23B onto the uppersurface of the glue-coated paper layer 32A.
In producing a three-dimensional interlaced decorative laminate, the three dimensional decoration sheet 23B, the glue-coated paper layer 32A and the substrate 33A are arranged as a stack into a heating-press machine (not shown). The stack is heated and pressed within the heating-press machine. Under the pressure, the glue film layer adheres the undersurface of the three dimensional decoration sheet 23B onto the uppersurface of the glue-coated paper layer 32 A. With a period of time of heating and pressure, the solid glue film layer on the undersurface of the glue-coated paper layer 32 A melts, thus adhering undersurface of the glue-coated paper layer 32A onto to the substrate 33A. It should be noted that it would be more difficult to adhere the three dimensional decoration sheet 23B directly onto the substrate 33 A because of the performance of materials (such as laminate, plastic and metal) of the substrate 33 A. With the use of the glue film layer on undersurface of the three dimensional decoration sheet 23B, it is easier to adhere the three dimensional decoration sheet 23 B onto the uppersurface of the glue-coated paper layer 32A, while the solid glue film layer on the undersurface of the glue-coated paper layer 32A has, after heating under pressure, much higher strength to adhere the substrate 33A.
Fig. 3 B is the second embodiment of the three-dimensional interlaced decorative laminate in the present invention. As shown in Fig. 3 B, underneath the three dimensional decoration sheet 23B, there is a substrate 33B (the corresponding part to reference number 3 shown in 4A). The substrate 33B can be wood board (such as core board, clip board, medium density board, and three-ply board, etc.), plastic board, metal board or other synthetic material board. hi the second embodiment shown in Fig. 3B, the three dimensional decoration sheet 23 B (which is coated with a glue film layer on its undersurface) and the substrate 33B are arranged as a stack into a cold-press machine (not shown) and adhere with each other through a cold pressure process. Alternatively, the three dimensional decoration sheet 23B and the substrate 33B are arranged into a heating-press machine (not shown) as a stack and adhere with each other through heat and pressure. Because it is easier to adhere the wood substrate 33B onto the undersurface of the three dimensional decoration sheet 23 B, the glue-coated paper layer 32A in the first embodiment can be left out and the glue film layer on the undersurface of the three dimensional decoration sheet 23B needs not to be selected as strictly as in the embodiment shown in Fig. 3A. However, if a substrate 33B were made of plastic board or metal board, the glue film layer needs to be selected strictly.
Fig. 4A is the sectional view of the three-dimensional interlaced decorative laminate according to the first embodiment (shown in Fig. 3A) of the present invention. As shown in Fig. 4A, the sectional view of the three-dimensional interlaced decorative laminate shows a first directional interlaced strip material 1 and the second directional interlaced strip material 2. The first directional fibre cloth strip layer 4 and the second directional fibre cloth strip layer 4' adhere to the undersurfaces of the first directional interlaced strip material 1 and the back side of the second directional interlaced strip material 2, respectively. The fibre cloth layer 5 adheres to the undersurface of interlaced surface sheet 16D which is interlaced by the first directional interlaced strip 1 and the second directional interlaced strip 2 (see reference 15C in Fig. 1C) and has an interlaced uppersurface with three dimensional effect. Underneath the fibre cloth layer 5, there is a glue film layer 6. Underneath the glue film layer 6, there is a glue-coated paper layer 7. Underneath the glue-coated paper layer 7, there is a substrate 3.
Fig. 4B is the sectional view of the three-dimensional interlaced decorative laminate according to the second embodiment (shown in Fig. 3B) of the present invention. As shown in Fig. 4B, the sectional view of the three-dimensional interlaced decorative laminate shows the first directional interlaced strip material 1 and the second directional interlaced strip material 2. The first directional fibre cloth strip layer 4 and the second directional fibre cloth strip layer 4' adhere to the undersurface of the first directional interlaced strip material 1 and the undersurface of the second directional interlaced strip material 2, respectively. The fibre cloth layer 5 adheres to the undersurface of interlaced surface sheet 16D which is interlaced by the first directional interlaced strip 1 and the second directional interlaced strip 2 (see reference 15C in Fig. 1C) and has an interlaced uppersurface with three dimensional effect. Underneath the fibre cloth layer 5, there is a substrate 3.
Figs. 5A-5D is a third embodiment of the three-dimensional interlaced decorative laminate in the present invention.
As shown in Fig. 5 A, three dimensional surface sheet 16D' is interlaced by a plurality of first directional strips and a plurality of second directional strips. In Fig. 5A, the materials for the first and second directional strips are formed by cutting the same material sheet used in the first and second embodiments (i.e., sheet 12A as shown Fig. IA). Comparing with the first and second embodiments, in the third embodiment, no layers are disposed on the undersurface of the sheet 12A when the sheet is cut into strips; there are no layers under the first and second directional strips when they are being interlaced into the three dimensional surface sheet 16D'. In other words, the three dimensional surface sheet 16D' is directly adhered onto a layer of fibre cloth (corresponding fiber cloth layer 5 in the first and second embodiments). Fig. 5B is a sectional view of three dimensional surface sheet 16D' showing the first and second directional strips.
Fig. 5C is a sectional view of three dimensional surface sheet 16D' showing the three dimensional surface sheet 16D' is adhered on to a fibre cloth 5 to form a three dimensional decoration sheet 23B'. It should be noted that the three dimensional decoration sheet 23 B' itself can be used as decoration materials to be adhered onto the surfaces of an article.
Fig. 5D is a sectional view of three dimensional surface sheet 16D' showing the three dimensional decoration sheet 23B' is adhered onto a substrate 3 to form the three-dimensional interlaced decorative laminate. It should be noted, the fibre cloth mentioned in the present invention is preferably to be non-woven cloth made of a chemical material such as polyester. This type of non- woven cloth does not absorb glue, and therefore can avoid the loss of the glue in the process of heat and/or pressure, and can avoid the occurrence of the circumstance where the glue is absorbed slowly during the use. Moreover, this type of non- woven cloth is higher in tenacity than the paper.
In the foregoing description, the present invention is illustrated by the embodiments, the description of which is used to exemplarily explain the principles of the present invention. The persons skilled in the field can be aware of any changes that do not go beyond the scope of the principles of the present invention, and therefore, the scope of protection asked for by the present invention is defined by the claims described in the specification of the present invention.

Claims

What is claimed is:
1. A three-dimensional decoration sheet, comprising: a first directional interlaced strip material (1) and a first fibre cloth strip layer (4), wherein, the uppersurface of the first fibre cloth strip layer (4) adheres to the undersurface of the first directional interlaced strip material (1), to form a first directional interlaced strip with the undersurface of the first fibre cloth strip layer (4); a second directional interlaced strip material (2) and a second fibre cloth strip layer (4'), wherein, the uppersurface of the second fibre cloth strip layer (4') adheres to the undersurface of the second directional interlaced strip material (2), to form a second directional interlaced strip with the undersurface of the second or fibre cloth strip layer (4'); the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet with the undersurface of the fibre cloth layer (5) coated with a glue film layer (6).
2. A three-dimensional decoration sheet according to Claim 1, characterized that of forming a decorative laminate with three-dimensional interlaced surface layer by further comprising: a glue-coated paper layer (7), which adheres to the glue film layer (6); a substrate (3), which adheres, through heat and/or pressure, to the three dimensional decoration sheet having the glue-coated paper layer (7), to form a decorative laminate with three-dimensional interlaced surface layer.
3. A decorative laminate with three-dimensional interlaced surface layer according to Claim 2, wherein, the first directional interlaced strip material (1) and the second directional interlaced strip material (2) are plant fibre, metal, plastic, emulational synthetic materials, linen, or cloth.
4. A decorative laminate with three-dimensional interlaced surface layer according to Claim 3, wherein, the substrate (3) is wood board, laminate board, plastic board, or metal board.
5. A decorative laminate with three-dimensional interlaced surface layer, comprising: a first directional interlaced strip material (1) and a first fibre cloth strip layer (4), wherein, the uppersurface of the first fibre cloth strip layer (4) adheres to the undersurface of the first directional interlaced strip material (1), to form a first directional interlaced strip with the undersurface of the first fibre cloth strip layer (4); a second directional interlaced strip material (2) and a second fibre cloth strip layer (4'), wherein, the uppersurface of the second fibre cloth strip layer (4') adheres to the undersurface of the second directional interlaced strip material (2), to form a second directional interlaced strip with the undersurface of the second fibre cloth strip layer (4'); the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet with the undersurface of the fibre cloth layer (5); a substrate (3), which adheres to the three dimensional decoration sheet, to form a decorative laminate with three-dimensional interlaced surface layer.
6. A decorative laminate with three-dimensional interlaced surface layer according to Claim 5, wherein, the first directional interlaced strip material (1) and the second directional interlaced strip material (2) are plant fibre, metal, plastic, emulational synthetic materials, linen, or cloth.
7. A decorative laminate with three-dimensional interlaced surface layer according to Claim 6, wherein, the substrate (3) is wood board, laminate board, plastic board, or metal board.
8. A fabricating method for fabricating a decorative laminate with three-dimensional interlaced surface layer, comprising: a step of providing a first directional interlaced strip material (1) and a first fibre cloth strip layer (4), wherein, the uppersurface of the first fibre cloth strip layer (4) adheres to the undersurface of the first directional interlaced strip material (1), to form a first directional interlaced strip with the undersurface of the first fibre cloth strip layer (4); a step of providing a second directional interlaced strip material (2) and a second fibre cloth strip layer (4'), wherein, the uppersurface of the second fibre cloth strip layer (4') adheres to the undersurface of the second directional interlaced strip material (2), to form a second directional interlaced strip with the undersurface of the second fibre cloth strip layer (4'); a step in which the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a step of providing a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet with the undersurface of the fibre cloth layer (5); a step of providing a glue-coated paper layer (7), which adheres to the glue film layer (6); a step of providing a substrate (3), which adheres, through heat and/or pressure, to the three dimensional decoration sheet having the glue-coated paper layer (7), to form a decorative laminate with three-dimensional interlaced surface layer.
9. A fabricating method for fabricating a decorative laminate with three-dimensional interlaced surface layer according to Claim 8, wherein, the first directional interlaced strip material (1) and the second directional interlaced strip material (2) are plant fibre, metal, plastic, emulational synthetic materials, linen, or cloth.
10. A fabricating method for fabricating a decorative laminate with three-dimensional interlaced surface layer according to Claim 9, wherein, the substrate (3) is wood board, laminate board, plastic board, or metal board.
11. A fabricating method for fabricating a decorative laminate with three-dimensional interlaced surface layer, comprising: a step of providing a first directional interlaced strip material (1) and a first fibre cloth strip layer (4), wherein, the uppersurface of the first fibre cloth strip layer (4) adheres to the undersurface of the first directional interlaced strip material (1), to form a first directional interlaced strip with the undersurface of the first fibre cloth strip layer (4); a step of providing a second directional interlaced strip material (2) and a second fibre cloth strip layer (4'), wherein, the uppersurface of the second fibre cloth strip layer (4') adheres to the undersurface of the second directional interlaced strip material (2), to form a second directional interlaced strip with the undersurface of the second fibre cloth strip layer (4'); a step in which the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a step of providing a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet with the undersurface of the fibre cloth layer (5); a step of providing a substrate (3), which adheres to the three dimensional decoration sheet having the glue-coated paper layer (7), to form a decorative laminate with three-dimensional interlaced surface layer.
12. A fabricating method for fabricating a decorative laminate with three-dimensional interlaced surface layer according to Claim 11, wherein, the first directional interlaced strip material (1) and the second directional interlaced strip material (2) are plant fibre, metal, plastic, emulational synthetic materials, linen, or cloth.
13. A fabricating method for fabricating a decorative laminate with three-dimensional interlaced surface layer according to Claim 12, wherein, the substrate (3) is wood board, laminate board, plastic board, or metal board.
14. A three dimensional decoration sheet, comprising: a first directional interlaced strip; a second directional interlaced strip; the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a fibre cloth layer (5), the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet.
15. A three-dimensional decoration sheet according to Claim 14, characterized that of forming a decorative laminate with three-dimensional interlaced surface layer by further comprising: a substrate (3) adhered to the three dimensional decoration sheet.
16. A three dimensional decoration sheet according to Claim 14, wherein, the first directional interlaced strip and the second directional interlaced strip are made from plant fibre, metal, plastic, emulational synthetic materials, linen, or cloth.
17. A fabricating method for fabricating a three dimensional decoration sheet, comprising: a step of providing a first directional interlaced strip; a step of providing a second directional interlaced strip; a step in which the first directional interlaced strip and the second directional interlaced strip interweave each other three-dimensionally or are interlaced together in a longitudinal-transversal way to form a three dimensional interlaced surface sheet layer; a step of providing a fibre cloth layer (5,) the uppersurface of which adheres to the undersurface of the three dimensional interlaced surface sheet layer, to further form a three dimensional decoration sheet.
18. A fabricating method for fabricating a three dimensional decoration sheet according to Claim 17, characterized that of forming a decorative laminate with three-dimensional interlaced surface layer by further comprising the steps of: adhering a substrate (3) onto the three dimensional decoration sheet.
19. A fabricating method for fabricating a three dimensional decoration sheet according to Claim 17, wherein, the first directional interlaced strip and the second directional interlaced strip are made of plant fibre, metal, plastic, emulational synthetic materials, linen, or cloth.
PCT/US2008/057851 2007-03-23 2008-03-21 Improved three-dimensional interlaced decorative laminate and its fabricating method WO2008118788A1 (en)

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