Abrading device and method of abrading a floor structure utilizing the same

An abrading device for abrading a floor structure comprises a first abrading assembly and a second abrading assembly. The first and second abrading assemblies each have a rotationally driven contact roll provided with a sleeve having a plurality of cutouts formed in a pattern thereon. An abrading belt is trained over the sleeve. A first oscillation assembly is connected to the first abrading assembly and oscillates the contact roll of the first abrading assembly in a first direction via a linear reciprocating motion. A second oscillation assembly is connected to the second abrading assembly and oscillates the contact roll of the second abrading assembly in a second direction via a linear reciprocating motion. The first and second abrading assemblies consecutively abrade a top surface of the floor structure with the pattern formed by the cutouts on the respective sleeves to form a distressed visible pattern thereon.

FIELD OF THE INVENTION

The present invention relates to an abrading device for abrading a substantially planar wood structure, such as a solid hardwood or engineered hardwood floor structure, and a method of abrading the same.

BACKGROUND OF THE INVENTION

It is known to hand scrape a top surface of a floor structure, such as a solid hardwood or engineered hardwood floor structure, to create a distressed visible pattern on the top surface thereof. This process is both time consuming and costly, because each of the floor structures must be hand-sculpted one at a time. It is therefore desirable to develop an abrading device that can quickly and cost effectively abrade the top surface of the floor structure while still providing an authentic distressed appearance on the top surface thereof.

BRIEF SUMMARY OF THE INVENTION

The invention relates to an abrading device for providing a distressed visible pattern on a top surface of a floor structure comprising a first abrading assembly and a second abrading assembly. The first and second abrading assemblies each have a rotationally driven contact roll provided with a sleeve having a plurality of cutouts formed in a pattern thereon. An abrading belt is trained over the sleeve. A first oscillation assembly is connected to the first abrading assembly and oscillates the contact roll of the first abrading assembly in a first direction via a linear reciprocating motion. A second oscillation assembly is connected to the second abrading assembly and oscillates the contact roll of the second abrading assembly in a second direction via a linear reciprocating motion.

The invention further relates to a method for providing a distressed visible pattern on a top surface of a floor structure, comprising: providing a first abrading assembly and a second abrading assembly, the first and second abrading assemblies each having a rotationally driven contact roll, the contact roll being provided with a sleeve having a plurality of cutouts formed in a pattern thereon, and an abrading belt trained over the sleeve; rotating the contact roll of the first abrading assembly while simultaneously oscillating the contact roll of the first abrading assembly in a first direction via a linear reciprocating motion; abrading a top surface of the floor structure with the first abrading assembly; rotating the contact roll of the second abrading assembly while simultaneously oscillating the contact roll of the second abrading assembly in a second direction via a linear reciprocating motion; and abrading the top surface of the floor structure with the second abrading assembly.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

FIG. 1shows a floor structure1according to an embodiment of the present invention. The floor structure1may be a single ply of solid or engineered hardwood or multiple plies of solid and/or engineered hardwood laminated together. As shown inFIG. 1, the floor structure1comprises a top surface2and a bottom surface3. The top surface2has a substantially continuous distressed visible pattern4formed therein. In the embodiment shown and described herein, the distressed visible pattern4comprises a plurality of substantially parallel raised portions10and recessed portions11, which are intermittent at varying locations12. First and second opposing side surfaces5,6extend substantially perpendicular to the top surface2and the bottom surface3. The first and/or second opposing side surfaces5,6are optionally provided with a locking member7. The locking member7may comprise, for example, a tongue8and a groove9. The tongue8and the groove9may optionally be provided with locking projections (not shown) and locking recesses (not shown). Because locking members for floor structures are well known in the art, further description thereof has been omitted. Further, it will be appreciated by those skilled in the art that although the floor structure1is shown and described herein as having a substantially rectangular or plank shape, that the floor structure1could be square or any other geometrical configuration.

FIG. 2shows an abrading device20for providing the distressed visible pattern4on the top surface2of the floor structure1. Because the general structure of the abrading device20described herein is well known in the art, only the improvements thereto with respect to providing the distressed visible pattern4on the top surface2of the floor structure1will be described in further detail herein. Examples of conventional abrading devices having the general structure of the abrading device20described herein are sold, for example, by Timesavers, Inc. located in Maple Grove, Minn.

As shown inFIG. 2, the abrading device20comprises a housing21containing a first abrading assembly22and a second abrading assembly23. The first abrading assembly22and the second abrading assembly23each comprise a contact roll24spaced from and positioned substantially underneath an idler roll25. The contact roll24and the idler roll25are mounted on substantially parallel shafts26,27, respectively, which are supported by a frame35(FIG. 3) of the housing21. The contact roll24and the idler roll35have a length in a longitudinal direction of about 52 inches. The contact roll24of the first abrading assembly22has a radius smaller than a radius of the contact roll24of the second abrading assembly23. The contact roll24of the first abrading assembly22has a radius, for example, of about 7 inches, and the contact roll24of the second abrading assembly23has a radius, for example, of about 16.5 inches.

As shown inFIG. 3, each of the contact rolls24consists of a cylindrical core28configured to axially receive the shaft26. The core28may be formed, for example, from steel tubing. A sleeve29encompasses the core28. The sleeve29may be formed from steel, hard plastic, or a rubber material, such as urethane rubber. The sleeve29is provided with a plurality of equally spaced and substantially parallel inclined grooves30that extend radially about the sleeve29. The grooves30permit radial expansion of the sleeve29in response to centrifugal force and dissipate heat. The sleeve29is also provided with a plurality of equally spaced and substantially parallel cutouts31that extend radially about the sleeve29in a direction substantially perpendicular to a longitudinal direction of the sleeve29. The cutouts31are substantially concave in shape and form a substantially scalloped pattern along the longitudinal direction of the sleeve29. The cutouts31are machined into the sleeve29over top of the grooves30.

In the illustrated embodiment, the cutouts31of the contact rolls24of the first abrading assembly22and the second abrading assembly23have a depth of about 0.015-0.020 inches. The cutouts31of the contact roll24of the first abrading assembly22have a width32smaller than a width32of the cutouts31of the second abrading assembly23. For example, the width32of the cutouts31of the contact roll24of the first abrading assembly22is about 1.0 inch, and the width of the cutouts31of the contact roll24of the second abrading assembly23is about 1.5 inches. It will be appreciated by those skilled in the art that the length of the contact rolls24, the radius of the contact rolls24, the shape of the cutouts31, the depth of the cutouts31and/or the width32of the cutouts31may be varied depending on the desired appearance of the distressed visible pattern4formed on the top surface2of the floor structure1.

As shown inFIG. 2, an abrading belt33, is trained over the contact roll24and the idler roll25. The abrading belt33is tensioned between the contact roll24and the idler roll25, for example, by an actuator (not shown) that moves the idler roll25towards and away from the contact roll24. Because actuators are well known in the art with respect to abrading devices, further description thereof has been omitted. The abrading belt33is configured such that the abrading belt33substantially covers the contact roll24and the idler roll25. The abrading belt33may have a width32, for example, of about 60 inches and a length, for example, of about 48 inches. The abrading belt33is provided with an abrading material34. In the illustrated embodiment, the abrading belt33is, for example, sandpaper having a grit size of about 80-240, and preferably about 120. It will be appreciated by those skilled in the art, however, that the material used for the abrading belt33, the material used for the abrading material34, the size of the abrading material34, and the bond between the abrading belt33and the abrading material34may be varied depending on the desired appearance of the distressed visible pattern4formed on the top surface2of the floor structure1.

As shown inFIG. 4, the first abrading assembly22and the second abrading assembly23are each rotationally driven by a drive motor36which is coupled to the shaft26of the contact roll24via drive pulleys37and a drive belt38. The first abrading assembly22and the second abrading assembly23are further provided with a first oscillation assembly39and a second oscillation assembly40, respectively. The first oscillation assembly39is configured to oscillate the first abrading assembly22in a first direction41substantially parallel to the longitudinal direction of the sleeve29via a linear reciprocating motion. The second oscillation assembly40is configured to oscillate the second abrading assembly23in a second direction42substantially perpendicular to the longitudinal direction of the sleeve29via a linear reciprocating motion. In the illustrated embodiment, the first direction41is substantially perpendicular to the second direction42. It will be appreciated by those skilled in the art that there are many conventional methods that can be employed to oscillate the first abrading assembly22in the first direction41and the second abrading assembly23in the second direction42. For example, in the embodiment shown and described herein, the first abrading assembly22and the second abrading assembly23are each oscillated via a linear slide. However, other oscillation mechanisms could be used, such as a linear bearing mechanism.

As shown inFIG. 4, the first abrading assembly22is oscillated in the first direction41via the first oscillation assembly39, which comprises a variable frequency drive43having a cam arm44extending there from. The cam arm44is attached to the shaft26via a cam bearing45. The cam bearing45has an offset of about 0.75 inches such that for every one revolution of the shaft26the contact roll24is driven about 0.75 inches in the first direction41. A programmable logic controller46is connected to the variable frequency drive43of the first oscillation assembly39. The programmable logic controller46controls the timing sequence (whether variable or deliberate) and the speed at which the first abrading assembly22is oscillated in the first direction41.

The second abrading assembly23is oscillated in the second direction42via the second oscillation assembly40, which comprises a variable frequency drive47coupled to a cam shaft48via sprockets49and a cam chain50. The contact roll24is driven in the second direction42by the eccentric about 0.007-0.012 inches. The programmable logic controller46is connected to the variable frequency drive47of the second oscillation assembly40. The programmable logic controller46controls the timing sequence (whether variable or deliberate) and the speed at which the second abrading assembly23is oscillated in the second direction42.

As shown inFIG. 1, a conveyor belt60is arranged underneath the contact rolls24of the first abrading assembly22and the second abrading assembly23. The conveyor belt60is supported below the contact rolls24by a platen (not shown). A displacement member (not shown) for effecting relative movement between the contact rolls24and the platen (not shown) may be further provided beneath the first abrading assembly22and the second abrading assembly23. The displacement member (not shown) is configured to accommodate for different thicknesses of the floor structure1. Because conveyor belts, platens, and displacement members are well known in the art with respect to abrading devices, further description thereof has been omitted.

A method for providing the distressed visible pattern4on the top surface2of the floor structure1utilizing the abrading device20will now be described in greater detail. As shown inFIG. 5, at least one of the floor structures1is advanced by the conveyor belt60toward and underneath the contact roll24of the first abrading assembly22such that the top surface2of the floor structure1has tangential contact with the abrading belt33of the first abrading assembly22. As the abrading belt33contacts the top surface2of the floor structure1, the abrading belt33deflects into the cutouts31. As a result, as the contact roll24rotates, the abrading belt33removes material on the top surface2of the floor structure1in a pattern corresponding to the pattern formed on the sleeve29by the cutouts31. For example, in the embodiment shown and described herein, a plurality of substantially parallel raised portions10and substantially parallel recessed portions11are formed on the top surface2of the flooring structure1, wherein the width, height, and location of the raised portions10substantial correspond to the width32, depth, and location of the cutouts31on the sleeve29. Simultaneously, the contact roll24is oscillated in the first direction41by the first oscillation assembly39in response to a signal from the programmable logic controller46. In the illustrated embodiment, the contact roll24is oscillated in a direction substantially parallel to the top surface2of the floor structure1. Thus, the oscillation of the contact roll24causes the pattern being formed on the top surface2of the floor structure1to deviate in the first direction41. As a result, in the embodiment shown and described herein, the substantially parallel raised portions10are inclined in the first direction41. The amount and timing of the deviation corresponds to the signal from the variable frequency drive43.

Next, the floor structure1is advanced by the conveyor belt60toward and underneath the contact roll24of the second abrading assembly23such that the top surface2of the floor structure1is in alignment with the contact roll24. As the floor structure1is advanced, the contact roll24is oscillated in the second direction42by the second oscillation assembly40in response to a signal from the programmable logic controller46. In the illustrated embodiment, the contact roll24is oscillated in a direction substantially perpendicular to the top surface2of the floor structure1. As a result, the abrading belt33comes into and out of contact with the top surface2of the floor structure1. When the abrading belt33contacts the top surface2of the floor structure1, the abrading belt33deflects into the cutouts31. As a result, as the contact roll24rotates, the abrading belt33removes material on the top surface2of the floor structure1in a pattern corresponding to the pattern formed on the sleeve29by the cutouts31. For example, in the embodiment shown and described herein, because the top surface2of the floor structure1already has the raised portions10and the recessed portions11formed therein, the abrading belt33mainly removes material from the raised portions10to cause the raised portions10to be intermittent at the varying locations12with respect to a longitudinal direction of the floor structure1. The amount and timing of the contact of the abrading belt33with the top surface2of the floor structure1corresponds to the signal from the variable frequency drive43.

As shown inFIG. 5, after the floor structure1exits the abrading device20, the top surface2of the floor structure1has the distressed visible pattern4formed thereon. The abrading device20shown and described herein therefore quickly and cost effectively abrades the top surface2of the floor structure1to provide an authentic distressed appearance on the top surface2thereof. After the distressed visible pattern4is formed on the floor structure1, the floor structure1may optionally be run through a finishing line (not shown) where stains and/or top coats, for example, can be applied to the top surface2of the floor structure1.

The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. For example, the teachings herein with respect to the abrading device20are not solely limited to floor structures. It will be appreciated by those skilled in the art that the abrading device20could also be used to provide the distressed visible pattern4on other wood or wood-like structures, such as wall or furniture structures. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents.