Method and apparatus for laminating ceramic tile

• US 6,641,696 B1
• Filed: 07/11/2000
• Issued: 11/04/2003
• Est. Priority Date: 07/11/2000
• Status: Expired due to Fees

• Current Assignee: David A. Edgerton
• Original Assignee: David A. Edgerton
• Inventors: Edgerton, David A.
• Primary Examiner(s): Crispino, Richard
• Assistant Examiner(s): Hawkins, Cheryl N.
• Application Number:
  US09/614,100
• Time in Patent Office: 1,211 Days
• Field of Search: 156/272.2, 156/275.7, 156/289, 156/277, 156/71, 156/306.6, 156/307.1, 156/307.7, 428/46, 428/47, 428/48, 428/50, 428/325, 428/326, 428/327
• US Class Current: 156/277
• CPC Class Codes: B32B 2037/0061 the apparatus being an office laminator
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 38/14 Printing or colouring
• CPC Class Codes: B32B 7/10 at least one layer having inter-reactive properties
• CPC Class Codes: B44C 1/1712 Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
• CPC Class Codes: B44C 5/0438 containing stone elements
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material

Abstract

A method of laminating a graphic sheet of material onto a substrate material, including the steps of positioning a substrate material, having a top and sides, into a desired position, disposing (a) at least one sheet of thermo-setting adhesive on the top of the substrate material, disposing (b) at least one opaque white melamine sheet on the at least one adhesive sheet, disposing the (c) graphic sheet of material on the at least one opaque white melamine sheet, disposing a (d) at least one clear sheet of melamine on the graphic sheet of material, disposing a (e) at least one release paper sheet on the at least one clear sheet of melamine, applying heat to the sheets a, b, c, d and e, and applying pressure to force said sheets a, b, c, d and e against the substrate to thereby cause bonding of said sheets a, b, c and d together and to the substrate. A preferred product produced by the method is formed with a ceramic tile as the substrate and a printed paper sheet as the graphic sheet of material.

Claims

1. A method of laminating a graphic sheet of material onto a substrate material, said method comprising:

positioning a substrate material, having a top and sides, into a desired position;

disposing (a) at least one sheet of thermo-setting adhesive on the top of said substrate material;

disposing (b) at least one opaque white melamine sheet on said at least one adhesive sheet;

disposing said (c) graphic sheet of material on said at least one opaque white melamine sheet;

disposing (d) at least one clear sheet of melamine on said graphic sheet of material;

disposing (e) at least one release paper sheet on said at least one clear sheet of melamine;

applying heat to said sheets sufficient to at least partially melt (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (d) the at least one clear sheet of melamine; and

applying pressure sufficient to force said sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material, (d) the at least one clear sheet of melamine and (e) the at least one release paper sheet, together and against said substrate to thereby cause (1) bonding of said thermo-setting adhesive to the substrate and (2) to cause (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material and (d) the at least one clear sheet of melamine to be cross-linked together.

2. The method of claim 1 wherein said sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material, (d) the at least one clear sheet of melamine and (e) the at least one release paper sheet are pressed over at least a portion of at least one side of said substrate material for causing the sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine, sheet, (c) the graphic sheet of material and (d) the at least one clear sheet of melamine to bond to said at least one portion of at least one side of the substrate material.

3. The method of claim 1 wherein said sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material, (d) the at least one clear sheet of melamine and (e) the at least one release paper sheet are pressed over at least portions of the sides of said substrate material for causing the sheets (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material and (d) the at least one clear sheet of melamine to bond to said portions of the sides of the substrate material.

4. The method of claim 1 wherein the substrate material used is a ceramic tile.

5. The method of claim 1 including using said (e) sheet of release paper which is textured so that a finished laminated product has a predetermined texture on it.

6. The method of claim 1 including printing a design on said graphic sheet.

7. The method of claim 1 including printing a desired graphic design on said graphic sheet of paper.

8. The method of claim 1 including printing a desired graphic design on said graphic sheet of paper using an ink jet printer.

9. The method of claim 1 wherein said sheets (b) the at least one opaque white melamine sheet and (d) the at least one clear sheet of melamine bond by cross linking through the (c) graphic sheet of material whereby the graphic sheet of material does not substantially lose the whiteness it had prior to said cross linking.

10. The method of claim 1 wherein the graphic sheet of material is 20 LB ink jet paper.

11. The method of claim 1 wherein the graphic sheet of material does not contain substantial amounts of melamine.

19. The article of manufacture of claim 9 wherein said sheets (b) the at least one opaque white melamine sheet and (d) the at least one clear sheet of melamine bond by cross linking through the (c) graphic sheet of material whereby the graphic sheet of material does not substantially lose the whiteness it had prior to said cross linking.

20. The article of manufacture of claim 9 wherein the graphic sheet of material is 20 LB ink jet paper.

21. The article of manufacture of claim 9 wherein the graphic sheet of material does not contain substantial amounts of melamine.

12. An article of manufacture prepared by a process comprising:

positioning a substrate material, having a top and sides, into a desired position;

disposing (a) at least one sheet of thermo-setting adhesive on the top of said substrate material;

disposing (b) at least one opaque white melamine-sheet on said at least one adhesive sheet;

disposing a (c) graphic sheet of material on said at least one opaque white melamine. sheet;

disposing (d) at least one clear sheet of melamine on said graphic sheet of material;

disposing (e) at least one release paper sheet on said at least one clear sheet of melamine;

applying heat to said sheets sufficient to at least partially melt (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (d) the at least one clear sheet of melamine; and

applying pressure sufficient to force said sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material, (d) the at least one clear sheet of melamine and (e) the at least one release paper sheet, together and against said substrate to thereby cause (1) bonding of said thermo-setting adhesive to the substrate and (2) to cause (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material and (d) the at least one clear sheet of melamine to be cross-linked together.

13. The article of manufacture of claim 12 wherein said sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material, (d) the at least one clear sheet of melamine and (e) the at least one release paper sheet are pressed over at least a portion of at least one side of said substrate material for causing the sheets (a) the at least one sheet of thermosetting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material and (d) the at least one clear sheet of melamine to bond to said at least one portion of at least one side of the substrate material.

14. The article of manufacture of claim 12 wherein said sheets (a) the at least one sheet of thermo-setting adhesive, (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material, (d) the at least one clear sheet of melamine and (e) the at least one release paper sheet are pressed over at least portions of the sides of said substrate material for causing the sheets (b) the at least one opaque white melamine sheet, (c) the graphic sheet of material and (d) the at least one clear sheet of melamine to bond to said portions of the sides of the substrate material.

15. The article of manufacture of claim 12 wherein the substrate material used is a ceramic tile.

16. The article of manufacture of claim 12 including using said (e) sheet of release paper which is textured so that a finished laminated product has a predetermined texture on it.

17. The article of manufacture of claim 12 including printing a design on said graphic sheet.

18. The article of manufacture of claim 12 including printing a desired graphic design on said graphic sheet of paper.