US20070261351A1

US20070261351A1 - Process for forming wood mosaics for floorings and coverings

Info

Publication number: US20070261351A1
Application number: US11/411,536
Authority: US
Inventors: Giovanni Fiorino; Demetrio Fiorino; Roberto Simonetti
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-04-26
Filing date: 2006-04-26
Publication date: 2007-11-15

Abstract

Formation of the mosaic is performed by joining a first sheet element made of plastic to a second sheet element made of wood, thus obtaining a bilayer laminate, which is subsequently cut into a plurality of elements. After an ageing treatment by abrasion, or by beveling, each element is placed internally of a template, a top surface of each element facing downwards at this point. A grid is glued onto the plurality of elements in the template. The mosaic thus formed is waterproofed and a mixture of sand and glue is deposited on a bottom surface of the mosaic.

Description

BACKGROUND OF THE INVENTION

The invention relates to a process for forming wood mosaics for floorings and coverings.
The prior art teaches various materials and laying processes for realizing floorings and coverings.
For example, laying ceramic, marble, cotto, stone or granite floorings is done using single-components, or simple cement mixed with sand and water on a preferably damp base.
If a wood flooring is to be laid, however, the wood elements have to be cemented using bi-component glues on specially-prepared and dry bases. Apart from the fact that the wood must never be wet during laying, it is strongly advised not to lay parquet floors in rooms where there is a potential contact with water, such as, for example, bathrooms and kitchens.
Therefore wood layers, generally carpenters by trade, are usually equipped only for parquet laying, while tilers use totally different equipment and laying processes which preclude their laying parquet floorings.
Where a mixed-type flooring is to be laid, for example wood and marble or wood and glass, or wood and granite, a very long laying process is needed. After the tiler has applied the non-wood materials using special cement mixes (special because they have to be combined with wooden elements), the laying process has to be halted for several days in order to let the flooring base dry out, before the carpenter can glue down the wooden elements.
The main aim of the present process is to obtain a mosaic which is based on wooden materials, which can be laid using the “normal” laying processes for floors.
A further aim of the present process is to obtain a wood-based mosaic which, in the case of a mixed-type flooring, can easily be laid by a single operative with considerable economic savings and a reduction in laying times.
A further aim of the present invention is to obtain a wood-based mosaic which can be laid in rooms that will potentially come into contact with water, for example bathrooms and kitchens, thus offering the same waterproof characteristics usually associated with ceramic, brick or stone type materials.
A further aim of the present invention is to obtain a wood-based mosaic which has the same characteristics of rigidity and surface resistance as marble or ceramic floors.
These aims and more besides are all achieved by the invention, as it is characterized in the appended claims.

SUMMARY OF THE INVENTION

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in detail with reference to the figures of the drawings, which illustrate a preferred but non-limiting embodiment of the invention.
FIG. 1 is a front view of a wood-based mosaic obtained using the process of the invention;
FIG. 2 is a first stage of a manufacturing process illustrating a first sheet-shaped element used for formation of a bi-layer laminate;
FIG. 3 is a second stage of the manufacturing process for pressure-formation of a bi-layer laminate defined by association of the first sheet-shaped element with a second sheet-shaped element;
FIG. 4 is a third stage of the manufacturing process involving varnishing of an upper layer of the bi-layer laminate.
FIG. 5 is a fourth stage of the manufacturing process in which the bi-layer laminate is cut into a plurality of modular elements;
FIG. 6 is a fifth stage of the manufacturing process, involving a surface abrasion process of the formed modular elements;
FIG. 7 is a sixth stage of the manufacturing process, in which the modular elements are laid on a shaped template in order to obtain a wood-based mosaic;
FIG. 8 is a seventh stage of the process in which the wood-based mosaic is waterproofed;
FIG. 9 is a final stage, in which the bottom surface of the wood-based mosaic is finished.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the figures of the drawings, 1 denotes in its entirety a wood-based mosaic for floorings and coverings.
The mosaic is defined by a plurality 2 of elements 3, each exhibiting a first lower layer 4 of plastic material and a second upper layer 5 of wood.
Each element 3 is distanced from the nearby others and stably fixed in proximity of the lower layer 4 thereof, on a support grid 16.
The formation of the mosaic 1 includes a series of stages described herein below.
A first sheet element 7, made of plastic and preferably a heat-hardened synthetic resin, is covered on a top surface thereof with a first layer of glue (9) (see FIG. 2).
A second sheet element 10 made of wood is laid on top of the first sheet element 7 (FIG. 3).
A press is used to join the two sheet elements 7 and 10, forming a bi-layer laminate (FIG. 4).
The two layers of the bi-layer laminate 11 thus obtained are inseparable thanks to the effect of the press and the adhesive power of the glue, which is preferably a single-component polyurethane glue.
Once the bi-layer laminate 11 has been formed the top surface 11 a thereof is given a first coat of varnish to give better workability thereof, especially of the second sheet element 10 made of wood, during the following work stages.
The first varnishing can also be done directly on the surface of the second sheet element 10 before it is coupled with the first sheet element 7 to form the bi-layer laminate 11.
A single-component varnish is used for the first varnishing stage.
When the varnish is dry, the bilayer laminate 11 is cut to obtain a plurality 2 of elements 3, each exhibiting a lower level 4 made of plastic and an upper level 5 made of wood.
The geometric shape of the elements 3 can be variously configured in several flat polygonal shapes, such as, for example, triangles, squares, rectangles or polygons, but the elements 3 can also be cut into curved irregular shapes.
Where the elements 3 are polygonal with linear sides, the cutting stage is done with a blade or a milling machine, while where the elements 3 are irregularly shaped the cutting stage is done using a water-jet process of known type.
Once the elements 3 have been made ready, the next stage of abrading is initiated.
This involves inserting the elements 3 into a rotary container 14 containing an abrasive mixture, especially fine sands.
The sand mixture, when rotated, generates an upper and lateral erosion of the elements 3 on the upper layer 5, i.e. the wood layer, while the surface roughness of the lower layer 4 made of plastic is not affected as it is very hard. The process can be substituted by one in which the edges of the elements 3 are beveled by removing material therefrom.
Both of the above treatments have the aim of improving the aesthetic appeal of the elements 3, giving them an antique effect and an irregular edge, different for each element 3.
At this point the mosaic 1 can be assembled using a template 13 having a sheet shape and exhibiting a series of recesses 14, each having a shape that follows the edge of the element 3.
In this stage, once the template 13 has been laid flat, each element 3 is laid internally of a recess 14 and positioned in order that the lower layer 4, made of resin, is facing upwards.
After applying a second layer of glue on the lower layer 4 of each element 3, a grid 16 is placed on the template 13.
The grid 16, preferably made of a synthetic material, enables the operative to maneuver a mosaic 1 structure of sufficiently large dimensions in order to accelerate the laying process.
When the template 13 is removed, the mosaic 1 is tipped over and the wood surface is waterproofed by means of a bi-component spray varnish.
The varnish is sprayed using nozzles 17 that are inclined with respect to the vertical, so that the varnish can reach and waterproof the edges of the elements 3.
When the waterproofing stage is completed, the mosaic 1 is again tipped over and the process is completed by depositing, in proximity of the bottom layer 4 of the elements 3 and therefore the grid 16, a mixture of sand and glue to give the mosaic a rough laying surface, typical of the surfaces of ceramic, stone and the like (FIG. 9).
Obviously, without forsaking the field of protection of the present process, the mosaic 1 can be given a second waterproofing on the wood surface, and the grid can be glued thereon, on the bottom layer 4 of each element 3.

Claims

1). A process for forming wood mosaics for floorings and coverings, comprising following stages:

spreading a first layer of glue on a first sheet element made of a synthetic material;

placing a second sheet element on the first sheet element, which second sheet element is made of wood, in order to create a bi-layer laminate;

pressing the bi-layer laminate until the glue is dry;

treating a top surface of the bilayer laminate with a waterproofing varnish; cutting the bi-layer laminate into a plurality of elements;

subjecting the plurality of elements to a process of surface abrasion internally of a container containing an abrasive mixture consisting mainly of sand;

locating the plurality of elements internally of a template in order to form a mosaic;

gluing a grid on the plurality of units, locating the grid in a position above the template;

varnishing the top surface of the mosaic, which top surface is wooden.

2). The process of claim 1, wherein following the varnishing of the top surface of the mosaic a bottom surface of the mosaic, comprising the grid, can be finished by applying a primer preferably consisting of glue and sand in order to create a laying surface.

3). The process of claim 1, wherein preferably a polyurethane glue is used for applying the first sheet element to the second sheet element.

4). The process of claim 1, wherein the treating the top surface of the bi-layer laminate can be performed before forming the laminate bilayer.

5). The process of claim 1, wherein the treating the top surface of the bi-layer laminate is performed by using a preferably single-component varnish.

6). The process of claim 1, wherein the cutting the bi-layer laminate into a plurality of elements is performed by means of a blade or a milling machine.

7). The process of claim 1, wherein the cutting the bilayer laminate into a plurality of elements is performed using a water-jet process.

8). The process of claim 1, wherein the subjecting the plurality of elements to a process of surface abrasion is performed by rotating a container containing sand.

9). The process of claim 1, wherein alternatively to the subjecting the plurality of elements to a process of surface abrasion, the plurality of elements can be beveled at edges thereof in proximity of the top surfaces thereof, in order to remove material therefrom.

10). The process of claim 1, wherein the varnishing the top surface of the mosaic is performed using a bi-component varnish.

11). The process of claim 10, wherein the varnishing a top surface of the mosaic is performed using at least a nozzle which is inclined with respect to the vertical.