US20070107650A1 - Marine flooring plate - Google Patents

Marine flooring plate Download PDF

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Publication number
US20070107650A1
US20070107650A1 US10573290 US57329004A US2007107650A1 US 20070107650 A1 US20070107650 A1 US 20070107650A1 US 10573290 US10573290 US 10573290 US 57329004 A US57329004 A US 57329004A US 2007107650 A1 US2007107650 A1 US 2007107650A1
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Prior art keywords
impregnated
high pressure
marine
marine flooring
characterized
Prior art date
Legal status (The legal status 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 status listed.)
Abandoned
Application number
US10573290
Inventor
Tom Hvaal
Matthias Fischer
Truls Strom
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Combi Craft AS
Original Assignee
Combi Craft AS
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Publication date
Family has litigation

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    • 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
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/06Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • 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
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/002Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • 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
    • B32B41/00Arrangements for controlling or monitoring lamination processes; Safety arrangements
    • 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
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B63SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63BSHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING
    • B63B5/00Hulls characterised by their construction of non-metallic material
    • B63B5/02Hulls characterised by their construction of non-metallic material made predominantly of wood
    • B63B5/06Decks; Shells
    • 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
    • B32B2260/00Impregnation or embedding of a layer; Bonding a fibrous, filamentary or particulate layer by using a binder
    • B32B2260/02Composition of the impregnated, bonded or embedded layer
    • B32B2260/028Paper layer
    • 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
    • B32B2260/00Impregnation or embedding of a layer; Bonding a fibrous, filamentary or particulate layer by using a binder
    • B32B2260/04Impregnation material
    • B32B2260/046Synthetic resin
    • 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
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554Wear resistance
    • 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
    • B32B2317/122Kraft paper
    • 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
    • B32B2317/125Paper, e.g. cardboard impregnated with thermosetting resin
    • 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
    • B32B2605/00Vehicles
    • B32B2605/12Ships

Abstract

A marine flooring plate designed for use as walking base in a boat is disclosed. The marine flooring plates is constructed of a High Pressure Laminate (HPL) having a body of kraft paper (P) impregnated with thermo setting binding agent, an upper layer in the form of a decorating paper (D) imprinted with wood structure and impregnated with resin and a wear resistant top layer in the form of a transparent paper (O) impregnated with resin. The body of the high pressure laminate has a through inked black or brown core. The wear resistant top layer and the upper layer having wood structure décor is machined in the depth (d) and into the black/brown body of the high pressure laminate by means of a milling tool. Thus seams (3, 4) are formed in the flooring plate in a predetermined pattern in order to imitate a marine flooring of natural wood.

Description

  • The present invention relates to a marine flooring plate designed for use as walking base in a boat, which marine flooring plate is constructed of a High Pressure Laminate (HPL) having a body, or core, of kraft paper impregnated with thermosetting binding agent, an upper layer in the form of a décor paper imprinted with wood structure and impregnated with resin and a wear resistant top layer in the form of a transparent paper impregnated with resin
  • The invention also relates to a method for manufacturing a marine flooring plate of the above said kind.
  • At present two main choices are available for flooring in leisure boats. One is genuine flooring of natural wood, frequently made of teak and is layed out as parquet with interstices between the individual boards, so called seams, and includes a surrounding frame work in the same level as the marine flooring. The interstices are either filled with tar, as in the past, or more modern, with black polyurethane based mounting glue which is joint filler that seals the interstice against water ingress. Normally, when the tar or joint filler is drying up, the seams will appear as being slightly recessed relative to the parquet level. This creates décor and demonstrates genuine ship flooring in a nice way.
  • The second choice is marine flooring plates that imitate genuine woodwork like teak floor. One type of marine flooring plates supplied today is made of High Pressure Laminate (HPL) having imprinted black or light seams. The High Pressure Laminate has a body of standard kraft paper, which is brown in colour, and is impregnated with phenolic resin. On top of the body a décor paper is laying. This is a paper imprinted with teak décor and 5 mm wide black/light seams spaced 50 mm apart and impregnated with melamine resin. The black seams imitate teak flooring assembled with tar in the joints, primarily for outdoor use, while the light seams imitate Ramin lists between the boards, normally used indoor. On top of the décor layer is a transparent overlay paper impregnated with melamine that provides high wear resistance to the product. Further may particular engraved calenders make a structure in the surface that provides boat floorings of HPL having black/light seams with a high friction coefficient for increased antiskid safety.
  • A first object with the present invention is to provide new generation marine flooring plates which in greater extent resemble the marine floorings of natural wood. First of all this applies to the seams, which until now have been lying in the same plane as the flooring surface. It is desirable to design the seams so that they appear recessed, or as a shallow cavetto, which far more clearly imitate a natural seam. Thus the visual impression of the marine flooring plate will become closer to the genuine product.
  • A second object with the present invention is to be able to manufacture marine flooring plates that also include an imitated surrounding framework. This will considerably improve the visual total impression of the marine flooring plate and still more approach the genuine product.
  • Moreover has it been an object with the present invention to provide a marine flooring plate with the new design without the need to increase the retail price substantially.
  • According to the present invention is a marine flooring plate of the introductory said kind provided which is distinguished in that the body of the high pressure laminate has a through inked black or brown core, that the wear resistant top layer and the upper layer having the wood structure décor is machined in the depth and down into the black/brown core of the high pressure laminate by means of a milling tool to form seams in the marine flooring plate in a predetermined pattern in order to imitate a marine flooring of natural wood having seams.
  • Preferably the high pressure laminate consists of approximately 60% paper and approximately 40% thermosetting binding agent.
  • Suitably the core of the high pressure laminate is impregnated with phenolic resin. The décor paper and the top layer are suitably impregnated with melamine resin.
  • The machining depth to form the seams will normally be in the order of magnitude 0.1 to 1.0 mm, and the machining width to form the seams will be in order of 3 to 10 mm, most customary approximately 5 mm.
  • According to the present invention a method of the introductory said kind is provided, which method is distinguished in that the wear resistant top layer and the upper layer having wood structure décor are depth machined and down into the black/brown core of the high pressure laminate by means of a milling tool to form seams in the marine flooring plate in a predetermined pattern to imitate a marine floor of natural wood having seams.
  • Suitably the milling tool is connected to a numeric controlled machine tool (CNC) having an option for programming of actual marine flooring plate patterns.
  • Usually a standard high pressure laminate plate is initially fixed on stable jigs by means of vacuum and is positioned relative to the milling tool and seams are milled in the plate to depths in order of magnitude 0.1 to 1.0 mm.
  • In a preferable embodiment the milling tool is arranged to take into account variations in thickness and curving, due to stress variations, in the plate by means of proximity sensors.
  • Other and further objects, features and advantages will appear from the following description of two for the time being preferred embodiments of the invention, which is given for the purpose of description, without thereby being limiting, and given in context with the appended drawings where:
  • FIG. 1A shows from above a leisure boat having marine flooring plates according to the present invention installed,
  • FIG. 1B shows the marine flooring plates of FIG. 1A in the form of a separate kit in which each flooring plate has individual appearance adapted to the configuration of the boat,
  • FIG. 2A shows one individual marine flooring plate in enlarged scale,
  • FIG. 2B shows a cross sectional view along line A-A in FIG. 2A,
  • FIG. 2C shows an enlarged view of the encircled part of FIG. 2B,
  • FIG. 3 shows a cross sectional view through a high pressure laminate to illustrate the layered construction of such a laminate, and
  • FIG. 4 shows a kit of marine flooring plates according to the prior art.
  • Reference is firstly made to figure IA showing from above a leisure boat 1. The boat 1 has a floor, or a walking course, which is made up by a number of marine flooring plates 2.
  • As it appears from FIG. 1B the boat flooring consists of a kit of marine flooring plates 2 a-2 f each having its individual configuration that is adapted to the internal contours of the boat 1.
  • FIG. 2A illustrates a marine flooring plate 2 d of the kit shown in FIG. 1B. The marine flooring plate has a number of transversally extending seams 4. The seams 4 run parallel to the outer contour of the marine flooring plate 2 d and together they imitate a framework around the marine flooring plate 2 d. The framework often imitates 50 mm wide boards that surround the flooring plate. In addition a number of apertures 5 are illustrated that can be used for fixing the marine flooring plate 2 d to the hull of the boat by means of screws. The apertures, however, may be omitted if the marine flooring plates 2 a-2 f are intended to be fixed to a boat hull by means of gluing or else. It is to be understood that the complete pattern of the seams 3, 4 is lying in level, as FIG. 2B suggests.
  • As mentioned, FIG. 2C shows an enlarged view of the encircled part of FIG. 2B and illustrates that the seams 3, 4 are recessed a depth d relative to the plane of the marine flooring plate. Typical depth will be in the range of 0.1 to 1.0 mm, normally about 0.2 mm. Typical width will be in the range of 3 to 10 mm, normally about 5 mm. In addition the edge of the seams 3, 4 can be inclined by an angle at relative to a vertical line. Typically the angle a will be in the range of 10° to 40°, normally about 30°. In addition the marine flooring can with advantage be grinded on the rear side.
  • FIG. 3 shows a cross sectional view through a high pressure laminate (HLP) that illustrates the layered construction of such a laminate. One layer adds typically approximately 0.2 mm. A high pressure laminate plate of 5 mm will consist of a body, or core, of approximately 25 layers of kraft paper P (about 60%) impregnated with thermosetting binding agent (about 40%). By supplying heat of about 120° C. and pressure of 7 MPa the binding agent and the hardening agent fuse in an irreversible chemical reaction out to a homogeneous, nonporous material having a density of approximately 1.4 g/cm3. The body has a through colored black or brown core.
  • A décor paper D with about the same thickness as above is lying on top of the kraft paper P. The décor paper D has an imitated wooden structure imprinted in the top surface thereof and is impregnated with melamine resin. On top of the décor paper D is a layer of transparent paper O impregnated with melamine which provides the laminate with a high wear resistance. Special engraved calenders make a structure in the surface that offers the marine flooring a high friction coefficient for suitable properties regarding antiskid safety.
  • FIG. 4 shows a kit of marine flooring plates 2′ according to the prior art as it is discussed in the ingress of the specification. The seams 4′ are in the form of impressed, parallel stripes in the plane and the framework is totally absent.
  • A method for production of a marine flooring plate 2 designed for use as walking base in a boat 1 will now be described. A plate of high pressure laminate (HPL) having standard dimensions is fixed by means of vacuum on stable jigs arranged in a factory. The base material to the jigs is as an example a 30 mm furniture plate (laminated plate), which is calibrated in thickness and milled on a NC operated top mill. According to desires/drawings are pieces of the plate milled out. The edges of the pieces are rounded off by a radius of 1 mm. By means of a spring-loaded key apparatus that senses possible thickness tolerances and curvatures in the HPL plates, 0.1 to 1.0 mm deep and about 5.0 mm wide grooves are milled through the décor layer so that the black (brown) color in the core paper appears. To mill the grooves, a special manufactured tool having diamond blade with a flank angle of 30° is used. This way of production makes it possible to precisely mill out the particular seam pattern the customer may desire.

Claims (11)

  1. 1. A marine flooring plate designed for use as walking base in a boat, which marine flooring plate is constructed of a High Pressure Laminate (HPL) having a body of kraft paper (P) impregnated with thermosetting binding agent, an upper layer in the form of a décor paper (D) imprinted with wood structure and impregnated with resin and a wear resistant top layer in the form of a transparent paper (O) impregnated with resin, characterized in that the body of the high pressure laminate has a through inked black or brown core, that the wear resistant top layer and the upper layer having wood structure décor is machined in the depth (d) and into the black/brown core of the high pressure laminate by means of a milling tool to form seams (3, 4) in the marine flooring plate in a predetermined pattern to imitate a marine flooring of natural wood having seams.
  2. 2. The marine flooring plate according to claim 1, characterized in that the high pressure laminate consists of approximately 60% paper and approximately 40% thermosetting binding agent.
  3. 3. The marine flooring plate according to claim 1, characterized in that the core of the high pressure laminate is impregnated with phenolic resin.
  4. 4. The marine flooring plate according to claim 1, characterized in that the décor paper (D) is impregnated with melamine resin.
  5. 5. The marine flooring plate according to claim 1, characterized in that the top layer (0) is impregnated with melamine resin.
  6. 6. The marine flooring plate according to claim 1, characterized in that the machining depth (d) to form the seams (3, 4) is in order of magnitude 0.1 to 1.0 mm.
  7. 7. The marine flooring plate according to claim 1, characterized in that the machining width to form the seams (3, 4) is in order of magnitude 3 to 10 mm.
  8. 8. A method for manufacture of a marine flooring plate designed for use as walking base in a boat, which marine flooring plate is constructed of a High Pressure Laminate (HPL) having a body of kraft paper impregnated with thermosetting binding agent, an upper layer in the form of a décor paper imprinted with wood structure and impregnated with melamine resin and a wear resistant top layer in the form of a transparent paper impregnated with melamine, said body of the high pressure laminate has a through inked black or brown core, characterized in that the wear resistant top layer and the upper layer having wood structure décor are depth machined and down into the black/brown core of the high pressure laminate by means of a milling tool to form seams in the marine flooring plate in a predetermined pattern to imitate a marine floor of natural wood having seams.
  9. 9. A method according to claim 8, characterized in that the milling tool is connected to a numeric controlled machine tool (CNC) having an option for programming of actual patterns of marine flooring plates.
  10. 10. A method according to claim 8, characterized in that a standard high pressure laminate plate initially is fixed on stable jigs by means of vacuum and is positioned relative to the milling tool and seams are milled in the plate to depths in order of magnitude 0.1 to 1.0 mm.
  11. 11. A method according to claim 8, characterized in that the milling tool is arranged to take into account variations in thickness and curving of the plate by means of proximity sensors.
US10573290 2003-09-26 2004-01-21 Marine flooring plate Abandoned US20070107650A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
NO20034298A NO325006B1 (en) 2003-09-26 2003-09-26 Dorkplate
NO20034298 2003-09-26
PCT/NO2004/000017 WO2005030569A1 (en) 2003-09-26 2004-01-21 Marine flooring plate

Publications (1)

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US20070107650A1 true true US20070107650A1 (en) 2007-05-17

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Family Applications (1)

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US10573290 Abandoned US20070107650A1 (en) 2003-09-26 2004-01-21 Marine flooring plate

Country Status (4)

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US (1) US20070107650A1 (en)
EP (1) EP1663770B1 (en)
DE (1) DE602004021190D1 (en)
WO (1) WO2005030569A1 (en)

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2943013A (en) * 1956-07-27 1960-06-28 Hurlbut Paper Company High ash content absorbent paper for the decorative laminating industry and a process for preparing the same
US3373071A (en) * 1964-03-26 1968-03-12 Gen Electric Laminates
US3483795A (en) * 1967-06-09 1969-12-16 North American Rockwell Closed loop feedback for machining
US3551241A (en) * 1967-08-23 1970-12-29 Formica Corp Process for producing a decorative laminate comprising transferring a film of a transparent noble thermosetting resin to a decorative sheet from a flexible release transfer sheet and removing the flexible release sheet after the heat and pressure consolidation step
US3648358A (en) * 1969-10-24 1972-03-14 Westinghouse Electric Corp Process for texturing the surface of high pressure laminates
US4636443A (en) * 1984-11-23 1987-01-13 Formica Corporation Decorative laminates and method of producing same
US5207172A (en) * 1990-11-30 1993-05-04 Luitgard Wolter Boat deck covering and method for applying same
US5755068A (en) * 1995-11-17 1998-05-26 Ormiston; Fred I. Veneer panels and method of making
US20030046895A1 (en) * 1999-11-08 2003-03-13 Haffner Curt Richard Water resistant edge of laminate flooring
US6539643B1 (en) * 2000-02-28 2003-04-01 James Hardie Research Pty Limited Surface groove system for building sheets
US7216461B1 (en) * 2002-08-16 2007-05-15 Clemmer Clay E System and method for forming surfaces using tiled components and product resulting therefrom

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB794099A (en) * 1953-12-22 1958-04-30 Needle Industries Ltd Improvements in or relating to the manufacture of sign members
DE3724231A1 (en) * 1987-07-22 1989-02-02 Repol Polyester Produkte Gmbh Multilayer ornament plate and method for manufacturing a multilayer ornament plate

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2943013A (en) * 1956-07-27 1960-06-28 Hurlbut Paper Company High ash content absorbent paper for the decorative laminating industry and a process for preparing the same
US3373071A (en) * 1964-03-26 1968-03-12 Gen Electric Laminates
US3483795A (en) * 1967-06-09 1969-12-16 North American Rockwell Closed loop feedback for machining
US3551241A (en) * 1967-08-23 1970-12-29 Formica Corp Process for producing a decorative laminate comprising transferring a film of a transparent noble thermosetting resin to a decorative sheet from a flexible release transfer sheet and removing the flexible release sheet after the heat and pressure consolidation step
US3648358A (en) * 1969-10-24 1972-03-14 Westinghouse Electric Corp Process for texturing the surface of high pressure laminates
US4636443A (en) * 1984-11-23 1987-01-13 Formica Corporation Decorative laminates and method of producing same
US5207172A (en) * 1990-11-30 1993-05-04 Luitgard Wolter Boat deck covering and method for applying same
US5755068A (en) * 1995-11-17 1998-05-26 Ormiston; Fred I. Veneer panels and method of making
US20030046895A1 (en) * 1999-11-08 2003-03-13 Haffner Curt Richard Water resistant edge of laminate flooring
US6539643B1 (en) * 2000-02-28 2003-04-01 James Hardie Research Pty Limited Surface groove system for building sheets
US7216461B1 (en) * 2002-08-16 2007-05-15 Clemmer Clay E System and method for forming surfaces using tiled components and product resulting therefrom

Also Published As

Publication number Publication date Type
WO2005030569A1 (en) 2005-04-07 application
EP1663770A1 (en) 2006-06-07 application
DE602004021190D1 (en) 2009-07-02 grant
EP1663770B1 (en) 2009-05-20 grant

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Owner name: COMBI CRAFT AS,NORWAY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HVAAL, TOM KR.;FISCHER, MATTHIAS;STROM, TRULS H.;SIGNINGDATES FROM 20060301 TO 20060320;REEL/FRAME:018502/0096