Abstract:
The present invention provides a method for inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a core structure or core substrate. The method of the present invention includes the steps of die cutting a preselected inlay design out of a laminate sheet, die cutting a congruent insert to be placed in the aperture left by the die cut design, securing the insert into the die cut design aperture, laminating with heat and pressure the laminate sheet to a core material, and conducting a finishing operation such as trimming to clean the excess laminate sheet from around the edges of the core material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 10/359,018, filed Feb. 4, 2003 and entitled “Laminate Inlay Process for Sports Boards”. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a method for creating an inlay pattern in a laminate sheet. More specifically, the present invention relates to a method for creating an inlay pattern in a laminate sheet and laminating the inlaid sheet into a composite laminate structure. The present invention finds particular utility for the top skin for a sports board, such as a snow sled or bodyboard. 
     BACKGROUND OF THE INVENTION 
     Laminate sheets are useful in a variety of manufacturing processes. Laminate sheets may be bonded together to form a composite structure having layers of different materials. For example, foam core structures may have protective layers of laminated sheets attached to the outer surface thereof. Typical uses are again, snow sleds and bodyboards. 
     SUMMARY OF THE INVENTION 
     The present invention provides a method for inlaying a design into a laminate sheet and bonding the inlaid laminate sheet to a core structure or core substrate. The method of the present invention includes the steps of die cutting a preselected inlay design out of a laminate sheet, die cutting a congruent insert to be placed in the aperture left by the die cut design, securing the insert into the die cut design aperture, laminating with heat and pressure the laminate sheet to a core material, and conducting a finishing operation such as trimming to clean the excess laminate sheet from around the edges of the core material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of laminate sheet having a die cut inlay design cut therein according to the present invention. 
         FIG. 2  is a plan view of a laminate sheet having a die cut inlay design removed, the laminate sheet having at least one different material characteristic than that of  FIG. 1 . 
         FIG. 3  is a plan view of the removed die cut inlay design from the laminate sheet of  FIG. 2 . 
         FIG. 4  is a plan view of the laminate sheet of  FIG. 1 , having the die cut inlay design removed, and showing the die cut inlay design of  FIG. 3  taped into the cut out of the laminate sheet of  FIG. 1 , shown positioned over a core structure indicated by dashed lines. 
         FIG. 5  is side view of the taped laminate sheet of  FIG. 4  being fed through a laminating device and bonded to the surface of a core structure. 
         FIG. 6  is a plan view of the laminate sheet of  FIG. 4  after it has been bonded to the core structure, showing the tape removed. 
         FIG. 7  is a laminated sheet according to the present invention after it has been bonded to a core structure, showing another embodiment of the die cut inlay design. 
         FIG. 8  is a laminated sheet according to the present invention after it has been bonded to a core, showing still another embodiment of the die cut inlay design. 
         FIG. 9  is a plan view of a laminate sheet having a die cut inlay design cut therein according to an embodiment of the present invention. 
         FIG. 10  is a plan view of a laminate sheet having a die cut inlay design cut therein according to an embodiment of the present invention. 
         FIG. 11  is a plan view of a laminate sheet having a die cut inlay design cut therein according to an embodiment of the present invention. 
         FIG. 12  is a plan view of the laminate sheet of  FIG. 9 , showing the die cut inlay design removed leaving an inlay aperture. 
         FIG. 13  is a plan view of the laminate sheet of  FIG. 10 , showing the die cut inlay design removed leaving an inlay aperture. 
         FIG. 14  is a plan view of the laminate sheet of  FIG. 11 , showing the die cut inlay design removed leaving an inlay aperture. 
         FIG. 15  is a plan view of the laminate sheet of  FIG. 9 , with die cut inlay design insert pieces from the inserts of the sheets of  FIGS. 10 and 11  inserted into the inlay aperture. 
         FIG. 16  is a plan view of the laminate sheet of  FIG. 10 , with die cut inlay design insert pieces from the inserts of the sheets of  FIGS. 9 and 11  inserted into the inlay aperture. 
         FIG. 17  is a plan view of the laminate sheet of  FIG. 11 , with die cut inlay design insert pieces from the inserts of the sheets of  FIGS. 9 and 10  inserted into the inlay aperture. 
         FIG. 18  is a plan view of the laminate sheet of  FIG. 15 , with a bonding sheet overlaid the inlay design. 
         FIG. 19  is a schematic side view of a bonding process for attaching the bonding sheet overlaid the inlay design to the laminate sheet. 
         FIG. 20  is a schematic illustration of the lamination of the laminate sheet to a sports board core. 
         FIG. 21  is a plan view of the laminate sheet of  FIG. 15 , shown bonded to a sports board core. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is a method for making and applying an inlaid laminate sheet to a core structure or core substrate, and is particularly useful for forming top skin designs on sports boards such as snow sleds and body boards. Top skin material may include polyethylene foam, in the range of about 1/16″ to ¼″ thick, and with a density in the range of about 4-8 lbs/ft 3 . A first laminate sheet  10  having a die cut inlay periphery or design  12  is shown in  FIG. 1 , and includes a surrounding expanse or portion  14  and an insert portion  16 . Insert portion  16  fills a die cut design aperture  18 . The shape and size of insert portion  16  and design aperture  18  are preselected, and are the same as the shape and size of inlay design  12 . 
       FIG. 2  shows a second laminate sheet  20 , which includes a congruent die cut inlay design  22  sized and shaped to match die cut design  12  of  FIG. 1 . Second laminate sheet  20  further includes a surrounding expanse or portion  24  surrounding die cut design  22 . An insert portion  26  has been removed from second laminate sheet  20  in  FIG. 2 , leaving a corresponding or matching design outline or aperture  28 . Insert portion  26  is shown isolated in  FIG. 3 , prior to its being inlaid in another sheet. 
     Laminate sheet  10  and laminate sheet  20  are different from one another in at least one material characteristic. For example, laminate sheet  10  may be red in color and laminate sheet  20  may be blue in color. Other color differences may exist between laminate sheet  10  and laminate sheet  20 . For example, laminate sheet  10  may be any color and laminate sheet  20  may be any other color including a lighter or darker shade of the same color as laminate sheet  10 . The idea is contrasting colors, to enhance the appearance of the laminated sheet. 
     Other material characteristics may be different between laminate sheet  10  and laminate sheet  20 . The surface properties of the sheets may be different. For example, sheet  10  may have a relatively low coefficient of friction and sheet  20  may have a relatively high coefficient of friction. Also the reverse may be true, and sheet  10  may have a relatively high coefficient of friction and sheet  20  may have a relative low coefficient of friction. Variation in the coefficient of friction may be the result of a surface treatment or an inherent material property. Increases in the coefficient of friction increase the purchase, or grip, that the surface has on an adjacent surface. 
     The matching die cut inlay designs  12  and  22  enable inserts  16  and  26  to be removed from sheets  10  and  20  and interchanged. Replacing insert  16  with insert  26  in sheet  10  makes a laminate sheet having an outer portion  14  of one material characteristic and an insert  26  of another material characteristic. Similarly, replacing insert  26  with insert  16  in sheet  20  makes a laminate sheet having an outer portion  24  of one material characteristic and an insert  16  of another material characteristic. The interchangeability may be used to enhance the characteristics of the composite structure. For example, if the composite structure is a snow sled or body board, an increase in the purchase of a rider surface may enhance the play value of the snow sled. The color of the insert may be different from that of the surrounding expanse, enhancing the visual aesthetics of the sports board. 
     Laminate sheet  10  may be a variety of polymer materials. For example, polyethylene, polystyrene, polypropylene, and polyvinylchloride may be used to form laminate sheet  10 . 
     A method of making an inlaid laminate sheet and applying it to a substrate, such as the foam core of a sports board, such as a snow sled, will be better understood with reference to  FIGS. 1-6 . Starting at  FIG. 1 , die cut design  12  is cut into laminate sheet  10 . Die cut design  12  may be cut using conventional stamping, like a “cookie cutter,” laser cutting, water jet cutting, or similar cutting techniques. Die cut design  12  forms separable insert portion  16 , which will be removed from laminate sheet  10  leaving an inlay aperture  18 . Inlay aperture  18  is sized to provide a corresponding periphery to receive an inlay piece to be inserted into laminate sheet  10 . 
     As shown in  FIG. 2 , an inlay piece has been removed from second laminate sheet  20  leaving an inlay aperture  28 . Insert portion, or inlay piece  26  is shown in  FIG. 3 . Inlay piece  26  is oriented to lie within inlay aperture  18  and secured to laminate sheet  10  by adhesive tape  30  stretched along and secured to opposites sides of the boundary defined by aperture  18 , as shown in  FIG. 4 . Inlay piece  26  may be inlaid and secured in place manually, or using an automated process. Laminate sheet  10 , with inlaid piece  26  taped into position or otherwise secured, is now shifted and placed directly over a substrate such as foam core  32 , shown in dashed lines in  FIG. 4 . That foam core defines the outline of a sports board, such as a snow sled or bodyboard. While inlay piece  26  is shown taped into position it should be understood that other suitable means for securing inlay piece  26  may be used, such as an adhesive layer, or electrostatic bonds, etc. 
     Laminate sheet  10  and substrate core  32  are then laminated together, as shown in  FIG. 5 . Substrate core  32  and laminate sheet  10  may be fed through a roll-press-laminating device  31 , and heat in the range of about 375° F. ensures lamination. The laminating device may include a pair of rollers  34  and  35  positioned to sandwich laminate sheet  10  and substrate core  32  together as indicated by arrows  36 . As shown in  FIG. 5 , roller  34  is adjacent laminate sheet  10  and may be heated to facilitate bonding between laminate sheet  10  and substrate core  32 . Roller  34  rotates in the direction, as indicated by arrow  38 , while roller  35  rotates in the opposite direction, as indicated by arrow  40 , to move both the substrate core  32  and laminate sheet  10  through the laminating device. 
     It can be seen that tape  30  may be secured in place while laminate sheet  10  is being bonded to substrate core  32  in the laminating device. Tape  30  ensures that inlay piece  26  remains properly aligned and secured in place during the laminating process. As a result of the laminating process, inlay piece  26  and laminate sheet  10  are both bonded in place to substrate core  32 . Thereafter, the tape  30  may be removed.  FIG. 6  shows laminate sheet  10  and inlay piece  26  bonded to substrate core  32  with tape  30  removed. 
     It should be understood that any die cut inlay design may be cut out of laminate sheets  10  and  20 , provided two requirements are met. The first is that the design dimensions are contained within the boundary of the exterior edge of substrate core  32 . The second requirement is that the design cut out of laminate sheet  10  be substantially the same size and shape as the design cut out of laminate sheet  20 . The aperture formed in the die cutting process is maintained within the boundaries of the laminate sheet. This is important because it is necessary to bond the sheet, using the inlay to the substrate core. 
     After the laminated sheet  10  and inlay piece  26  have been laminated onto substrate core  32 , the loose edges of the sheet are “heeled” around the chine and edges of the board, and are laminated to the chine by a heat gun. Excess material is then suitably trimmed away with a knife. 
     In the process shown, the laminate sheets may be sized about 22″ wide by 46″ or so in length, suitable for snow sled and bodyboard constructions. 
     The present invention avoids wastage of laminate sheet material in a production process. For example, as a die cut is made on one sheet to create an inlay portion, that first sheet is then available to receive an inlay portion or insert from a second sheet of material. Simultaneously, the second sheet is available to receive an inlay portion from the first sheet or some other sheet having a matching or congruent inlay design. 
     It should also be understood that the above-described process may be repeated on laminate sheet  20  with inlay piece  16  to form a composite with the material characteristics of laminate sheet  10  in the inlay design and the material characteristics of laminate sheet  20  in the surrounding portion. 
       FIGS. 7 and 8  show other embodiments of inlaid laminate sheets  110  and  210  respectively. Inlaid laminate sheet  110 , having an inlaid piece  126  of a different design from inlaid piece  26 , is bonded to a core substrate  132 . Similarly, inlaid laminate sheet  210 , having an inlaid piece  226  of a different design than inlaid pieces  26  or  126 , is bonded to a core substrate  232 . 
       FIGS. 9-21  illustrate yet another embodiment of the present invention, using a more complex die cut inlay design and three different laminate sheets. Some characteristic property of each laminate sheet is different from the other two laminate sheets, for example, the three sheets may all be different colors. While the example below, illustrated in  FIGS. 9-21 , includes three different laminate sheets, other combinations of more that three laminate sheets may be used in accordance with the present invention. 
       FIGS. 9 and 12  show a first laminate sheet top skin  310 , similar to that described above. Top skin  310  includes a first characteristic property, for example, a yellow color. A die cut design, or inlay periphery  312  is cut into top skin  310 . Die cut design  312  includes three sections or parts. A first section  312   a  defines a first portion of the design  312 . A second section  312   b  defines a second portion of design  312 . A third section  312   c  defies a third portion of design  312 . 
     The three portions or sections  312   a ,  312   b , and  312   c  combine together to form the entire die cut design  312 . An expanse  314  of top skin  310  is sized to surround die cut design  312 . Sections  312   a ,  312   b , and  312   c  define the boundaries of a set of design inserts  316 . Set of design inserts  316  includes a first insert  316   a , which is bounded by design section  312   a . Set of design inserts  316  includes a second insert  316   b , which is bounded by design section  312   b . Finally, set of design inserts  316  includes a third insert  316   c , which is bounded by design section  312   c.    
     An aperture  318 , shown more clearly in  FIG. 12 , is formed when each of inserts  316   a ,  316   b , and  316   c , are removed from within expanse  314 . Aperture  318  is sized to accommodate each of the inserts of set  316  when the inserts are arranged in a proper configuration, similar to the pieces of a puzzle. It will be understood that multiple designs may be used, and the design illustrated is  FIGS. 9-21  is not limiting, but merely used for purposes of illustration. 
       FIGS. 10 and 13  show a second laminate sheet top skin  320 , similar to that described above. Top skin  320  includes a second characteristic property different from top skin  310 &#39;s first characteristic property. For example, top skin  320  may include a blue color. A die cut design, or inlay periphery  322  is cut into top skin  320 . Like die cut design  312 , die cut design  322  includes three sections or parts. A first section  322   a  defines a first portion of design  322 . A second section  322   b  defines a second portion of design  322 . A third section  322   c  defines a third portion of design  322 . 
     The three portions or sections  322   a ,  322   b , and  322   c  combine together to form the entire die cut design  322 . An expanse  324  of top skin  320  is sized to surround die cut design  322 . Sections  322   a ,  322   b , and  322   c  define the boundaries of a set of design inserts  326 . Set of design inserts  326  includes a first insert  326   a , which is bounded by design section  322   a . Additionally, set of design inserts  326  includes a second insert  326   b , which is bounded by design section  322   b . Finally, set of design inserts  326  includes a third insert  326   c , which is bounded by design section  322   c.    
     An aperture  328  is formed when each of inserts  326   a ,  326   b , and  326   c , are removed from within expanse  324 , as shown in  FIG. 13 . Aperture  328  is sized to accommodate each of the inserts of set  326  when the inserts are arranged in a proper configuration, similar to the pieces of a puzzle. 
     It should be noted that die cut design  322  is a congruent to die cut design  312 . That is to say that die cut design  312  and  322  are sized and shaped such that each part of the design match. Therefore, insert  316   a  and insert  326   a  are sized and shaped to match. Similarly, insert  316   b  and  326   b  are sized and shaped to match. Finally, insert  316   c  and  326   c  are sized and shaped to match. Because of the congruent size and shape of the inserts, the inserts become interchangeable when producing inlay patterns, as will be explained in more detail below. 
       FIGS. 11 and 14  show a third laminate sheet top skin  340 , which is similar to that described above. Top skin  340  includes a third characteristic property different from both the first characteristic property of top skin  310  and second characteristic property of top skin  320 . For example, the their characteristic property may be a black color. 
     As was the case with top skins  310  and  320 , a die cut design, or inlay periphery  342  is cut into top skin  340 . Die cut design  342  includes three sections or parts. A first section  342   a  defines a first portion of the design  342 . A second section  342   b  defines a second portion of design  342 . A third section  342   c  defines a third portion of design  342 . 
     The three portions or sections  342   a ,  342   b , and  342   c  combine together to form the entire die cut design  342 . An expanse  344  of top skin  340  is sized to surround die cut design  342 . Sections  342   a ,  342   b , and  342   c  define the boundaries of a set of design inserts  346 . Set of design inserts  346  includes a first insert  346   a , which is bounded by design section  342   a . Set of design inserts  346  includes a second insert  346   b , which is bounded by design section  342   b . Finally, set of design inserts  346  includes a third insert  346   c , which is bounded by design section  342   c.    
     An aperture  348  is formed when each of inserts  346   a ,  346   b , and  346   c  are removed from within expanse  344 , as shown in  FIG. 14 . Aperture  348  is sized to accommodate each of the inserts of set  346  when the inserts are arranged in a proper configuration, similar to the pieces of a puzzle. 
     It should be noted, similar to as discussed above with reference to die cut designs  312  and  322 , that die cut design  342  is a congruent to die cut designs  312  and  322 . That is to say that, die cut design  312 ,  322  and  342  are sized and shaped such that each part of the design match. Therefore, insert  316   a , insert  326   a , and insert  346   a  are sized and shaped to match. Similarly, insert  316   b , insert  326   b , and insert  346   b  are sized and shaped to match. Finally, insert  316   c , insert  326   c , and insert  346   c  are sized and shaped to match. Because of the congruent size and shape of the inserts the inserts become interchangeable when producing inlay patterns, as will be explained in more detail below. 
       FIGS. 15-17  show how the three top skins  310 ,  320 , and  340  may be assembled to form three different inlay designs without wasting any of the material from the die cut process. As shown in  FIG. 15 , the aperture  318  of tops skin  310  may be filled with inserts cut out of top skins  320  and  340  to form a composite inlay design in the aperture. As shown, insert  326   a ,  346   b , and  326   c  are used to fill inlay aperture  318  of top skin  310  and form a composite inlay design. 
     As shown in  FIG. 16 , the aperture  328  of top skin  320  may be filled with inserts cut out of tops skins  310  and  340 . As shown, inserts  346   a , 316   b  and  346   c  are used to fill inlay aperture  328  of top skin  320  to form a composite inlay design. 
     As shown in  FIG. 17 , the aperture  348  of top skin  340  may be filled with inserts cut out of tops skins  310  and  320 . As shown, inserts  316   a ,  326   b , and  316   c  are used to fill inlay aperture  348  of top skin  340  to form a composite inlay design. 
       FIG. 18 , shows top skin  310  with the composite inlay design described with reference to  FIG. 15 . A layer of bonding material  350  overlaid on the composite insert may be used to secure the insert pieces of the inlay pattern in place, as will be further explained with reference to  FIG. 19 . The bonding material may be a thin polyethylene sheet, or any suitable material capable of holding the composite inlay in place. Bonding material  350  may include an adhesive, or may only bond to the top skin upon application of heat and pressure. 
       FIG. 19  illustrates a method securing bonding material  350  to top skin  310  for holding the composite inlay design in place. A heat source  352  may be used in conjunction with a Teflon, or similar non-stick layer  354  to prevent bonding material  350  from sticking to heats source  352 . Heat and pressure may be applied to bonding material  350  to provide a uniform bonding to top skin  310 . It will be understood that, the bonding step may be carried out by using a heat source, such as an iron of the type typically used to iron clothes, to bond the bonding layer to top skin  310 . In that case the process is carrier out by hand and a sheet of Teflon or other nonstick material separates the iron from the bonding layer to prevent it from sticking to the iron. 
       FIG. 20  illustrates a lamination process similar to that described with reference to  FIG. 5  above. However, top skin  310  is flipped over so that the side being bonded to sports board core  332 , is the side of the top skin that includes the bonding material  350 . So as shown, top skin  310  and substrate core  332  may be fed through a roll-press-laminating device  331 , and heat in the range of about 375° F. ensures lamination. The laminating device may include a pair of rollers  334  and  335  positioned to sandwich top skin  310 , bonding layer  350 , and substrate core  332  together as indicated by arrows  336 . Roller  334  is adjacent top skin  310  and may be heated to facilitate bonding between top skin  310  and substrate core  332 . Roller  334  rotates in a first direction, as indicated by arrow  338 , while roller  335  rotates in a second opposite direction, as indicated by arrow  339 , to move both the substrate core  332  and top skin  310  through the laminating device. 
     After lamination is complete, a sports board having a composite inlay including insert  326   c ,  346   b , and  326   a , has been formed, as shown in  FIG. 21 . It should be understood that sports board with composite inlays having different combinations of inserts may be formed using the same process described for the sports board shown in  FIG. 21 . For example, a sports board having a composite inlay having inserts  346   a ,  316   b , and  346   c  may be use to form a composite inlay from top skin  320 . Additionally, as another example, a sports board having a composite inlay having inserts  316   a ,  326   b , and  316   c  may be use to form a composite inlay from top skin  340 . 
     It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. 
     Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed in a related application. Such claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to any original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.