Abstract:
A laminated panel comprises a core layer and two fusible layer portions. The core layer has an upper surface. The fusible layers each have an upper surface with a surface finish and a lower surface. The lower surface of the first fusible layer portion is secured to the upper surface of the core layer, exposing the first surface finish. The lower surface of the second fusible layer portion is secured to at least one of the upper surface of the core layer and the upper surface of the first fusible layer portion, exposing the second surface finish. The two fusible layer portions are positioned side by side and are fused to be coplanar. A method for laminating panels is also provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present patent application claims priority on U.S. provisional Patent Application No. 61/352,992, filed on Jun. 9, 2010, and incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to laminated panels and to a lamination process and, more particularly but not exclusively, to a process for laminating various layers into a laminated panel with dual finishes, for subsequent use of the laminated panel as a component of a boot quarter, and of other sporting goods or the like. 
     2. Background Art 
     Laminated panels are found in a plurality of products. Laminated panels typically consist of a plurality of layers, each layer being part of the laminated panels for given properties. Therefore, laminated panels are used as an alternative to well known materials, such as leather and polymers (e.g., vinyl), in the fabrication of goods. 
     The layers constituting laminated panels are chosen for various properties that will suit the subsequent use of the product. For instance, layers having properties such as resilience, impermeability, strength, shock absorption and softness are combined to be laminated into panels that will have selected characteristics. 
     The laminated panels are subsequently cut into desired shapes so as to define a component of the product. For instance, a laminated panel may be cut into boot quarters. In such cases, various other components are secured to the boot quarter to form the boot (shoes, boots, skates, etc.). 
     Strips of material are often secured (e.g., sewn) to the boot quarter so as to add ornamental and functional features to the boot quarter. For instance, strips of vinyl or the like are provided on a heel portion of the boot quarter to improve the structural integrity of the boot, and to give a specific look to the boot. Similarly, reinforcement strips are often provided in the shoelace eyelet section of the boot quarter, to enhance the tear resistance of this area. 
     The laminated panel often remains partially exposed, and is therefore constituted of materials having a desired appearance. For instance, nylon meshing and polymeric materials such as Surlyn™ are commonly used to make up the outer layer of laminated panels. In a combination, nylon meshing is laminated to produce embossing effects. In addition to adding some structural integrity to the boot quarter, the embossing effects have ornamental value, in that logos, and designs can be produced in the laminated panel, and therefore enhance the ornamental value of the boot. 
     On the other hand, materials with such appealing finishes are often relatively expensive. Considering that parts of the laminated panel making up the boot quarter are often concealed behind other strips of material (e.g., vinyl), having laminated panels with outer layers fully made of such expensive materials does not represent a cost-effective solution. However, as boot quarters represent the structure of boots, it is not possible to reduce the size of the boot quarter. 
     SUMMARY OF INVENTION 
     It is therefore an aim of the present invention to provide a laminated panel that addresses the issues associated with the prior art. 
     Therefore, in accordance with the present invention, there is provided a laminated panel comprising: a core layer having an upper surface; a first fusible layer portion having an upper surface with a first surface finish and a lower surface, the lower surface of the first fusible layer portion being secured to the upper surface of the core layer such that the first surface finish is exposed; and a second fusible layer portion having an upper surface with a second surface finish and a lower surface, the lower surface of the second fusible layer portion being secured to at least one of the upper surface of the core layer and the upper surface of the first fusible layer portion such that the second surface finish is exposed, the first fusible layer portion and the second fusible layer portion being positioned side-by-side and fused so as to be coplanar at a meeting line therebetween. 
     Further in accordance with the present invention, there is provided a method for laminating panels comprising: receiving at least a core layer, a first fusible layer portion and a second fusible layer portion; positioning the first fusible layer portion and the second fusible layer portion side-by-side on the core layer; and fusing the first fusible layer portion and the second fusible layer portion to the core layer, in such a way that the first fusible layer portion and the second fusible layer portion are coplanar at a meeting line between one another. 
     It is pointed out that, although the claims refer to the various layers and layer portions as having an upper surface and a lower surface, the upper and lower terminology is used to clarify the reference to either side of the layers and the layer portions. These expressions are not meant to indicate that the layers and layer portions are always used in a given orientation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof and in which: 
         FIG. 1  is a perspective view of a skate having a boot quarter made of a laminated panel constructed in accordance with embodiments of the present invention; 
         FIG. 2  is an exploded view of the laminated panel constructed in accordance with a first embodiment of the present invention; 
         FIG. 3A  is an exploded view of the laminated panel constructed in accordance with a second embodiment of the present invention; 
         FIG. 3B  is an exploded view of the laminated panel constructed with additional films in accordance with the second embodiment; 
         FIG. 4  is a perspective view of the laminated panel of  FIG. 2 , with respect to press plates prior to the lamination process; 
         FIG. 5  is a perspective view of the laminated panel of  FIG. 2 , after the lamination process; and 
         FIG. 6  is a perspective view of the laminated panel of  FIG. 2 , after being die-cut into a boot quarter. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, and more particularly to  FIG. 1 , a skate, constructed with a laminated panel of the embodiments, is generally shown at  10 . The skate  10  has a boot  11  for accommodating the foot of the wearer, and a blade portion  12  projecting downwardly from the boot  11 . As is well known, the blade portion  12  is the interface between the skater and the ice during skating action. 
     The boot  11  has a boot quarter  13  making up a structure of the boot  11 . The boot quarter  13  covers the sides of the foot as well as the heel portion and a part of the ankle. A plurality of eyelets  14  are provided to receive a lace. A tongue  15  is associated with the boot quarter  13  to cover a front portion of the wearer&#39;s foot/heel, while being displaceable to allow entry/withdrawal of the foot from the skate  10 . 
     A nose  16  protrudes from a front portion of the skate  10  and covers the toes of the wearer. The nose  16  in the illustrated embodiment is associated with both the boot quarter  13  and the tongue  15 . A sole portion  17  is at a bottom of the boot  11 , and relates the boot quarter  13  to the blade portion  12 . 
     The boot quarter  13  is made of a main laminated panel  20 , upon which are secured (e.g., sewn) various strips of material. For instance, in the skate  10  of  FIG. 1 , a heel layer  21  covers a heel portion of the boot  11 . The heel layer has a pair of wings  21 A covering the ankle portion and merging with eyelet strips  22  (only one of which is visible in  FIG. 1  because of the point of view). Lateral strips  23  (one of which is visible in  FIG. 1 ) are adjacent to the nose  16  of the boot  11 . 
     The heel layer  21 , eyelet strip  22  and lateral strip are disposed such that the laminated panel  20  has an exposed portion  24 , with optional embossing  25 . It is observed however that a remainder of the laminated panel  20  of the boot quarter  13  is covered by the layer  21 , and strips  22  and  23 . In view of this, the construction of the laminated panel  20  is described. 
     Referring to  FIG. 2 , the laminated panel  20  is exploded to illustrate its various layers. The laminated panel  20  has an outer layer  30 , a core  31  and an inner layer  32 . Although the laminated panel  20  is illustrated as having three layers, fewer or more layers could be provided in the laminated panel  20 . 
     The outer layer  30  is partly exposed (i.e., the exposed portion  24 ) and partly covered (i.e., by layer  21  and strips  22 - 23 , as mentioned previously) in the shoe/boot. The outer layer  30  therefore consists of various materials providing a dual finish to the laminated panel  20 , with a coplanar relationship between adjacent finishes at a meeting line therebetween. 
     More specifically, for the exposed portion  24  ( FIG. 1 ), precut patterns  30 A of material are provided and are positioned accordingly on the outer layer  30 . For instance, the pair of patterns  30 A are made of a thermofusible material, such as Surlyn ™ (a thermopoastic ionomer resin), a plastic, carbon fiber sheets and other composite materials, nylon, a felt, a mesh polyester or the like, that has a selected finish. As an example, the pair of patterns  30 A may be a combination of a nylon mesh and Surlyn ™ interacting to create an embossing effect, as is the case for  FIG. 2 . 
     A backing layer portion  30 B of the outer layer  30  is made of a thermofusible material of lesser price, as the material will be covered. Accordingly, a reinforcement material, such as a plastic, a felt or the like, are well suited to be used as backing layer portion  30 B. It is pointed out that the backing layer portion  30 B may be without cutouts opposite the patterns  30 A, considering that both the patterns  30 A and the layer portion  30 B are thermofusible and will be fused to one another. 
     It is pointed out that the backing layer portion  30 B may have a pair of superposed materials, with a mesh to encapsulate a thermofusible material to add structural integrity to the outer layer  30 . Also, a thermofusible glue film  30 C may be used to adhere the patterns  30 A to the backing layer portion  30 B. 
     The core  31  is chosen as a function of the use of the shoe/boot. For instance, padding is typically required, whereby an expanded polymer is well suited to be used as the material of the core  31 . Expanded polymers considered for the core  31  are expanded polypropylene (i.e., EPP), expanded polyethylene (i.e., EPE), Arcel™, or the like. 
     An adhesive may be required between the outer layer ad the core  31 . In such a case, a glue such as a thermofusible glue film  35  can be used between the outer layer  30  and the core  31 . 
     The inner layer  32  is typically exposed in an interior of the boot, whereby the material used is typically a fabric or like soft material or fabric. For instance, a polyester fabric is typically used as the inner layer  32 . Depending on the types of material used for the core  31  and the inner layer  32 , an adhesive may be required to suitably secure the core  31  to the inner layer  32 . 
     Referring to  FIG. 4 , the laminated panel  20  is illustrated with press plates  40  prior to being laminated. As seen in  FIG. 4  an upper press plate has cutouts  41 , so as to produce embossing on the laminated panel  20 . Additional process layers such as antiadhesive sheets may be used to protect the laminated panel  20  from sticking to the surfaces of a lamination press. 
     In order to be laminated, the components of the laminated panel  20  are superposed above one another as required, with applicable adhesives (e.g., thermofusible glue film). A lamination press then applies pressure (by compression) to the laminated panel  20  sandwiched between the press plates  40 , and transfers heat simultaneously. 
     The combination of heat and pressure will result in the merging of the patterns  30 A with the backing layer portion  30 B to form a uniform surface, with embossing  25 , as seen in  FIG. 5 . Suitable press settings will ensure that the laminated panel  10  exiting the press has a generally uniform thickness, other than at the embossing  25 . More specifically, as the outer layer  30  has both the patterns  30 A and the backing layer portion  30 B made of thermofusible material, these components will both fuse under the action of heat from the press, and the pressure of the press will equalize the thickness of the laminated panel  20 . 
     Simultaneously, the heat and pressure from the press will result in the interconnection of the outer layer  30 , the core  31  and the inner layer  32 , whether through the use of adhesive or through compatible reactions between the materials. 
     Therefore, as seen in  FIG. 5 , the patterns  30 A and the backing layer portion  30 B form the outer layer  30 , but are flush with one another in a plane of the outer layer  30  due to the fusion reaction. The embossing  25  may be a mesh material (e.g., nylon mesh) protruding out of the surface of the outer layer  30  (as a function of the cutouts  41  in the press plates in  FIG. 4 ), and encapsulated elsewhere in either the material of the patterns  30 A or in the backing layer portion  30 B. 
     Referring to  FIG. 6 , the laminated panel  20  is then cut to the selected shape of the boot quarter  13 . In the illustrated embodiment, a symmetry line A represents a central axis positioned at the center of the heel portion of the skate  10 . When the layer  21  and strips  22  and  23  are secured to the boot quarter  13 , only the material of the patterns  30 A and the embossing  25  will be visible ( FIG. 1 ). This results in the dual finish of the laminated panel  20 . 
     It is pointed out that although the boot quarter  13  is illustrated as being used for skates, other uses are contemplated, such as walking boots, ski boots and other footgear. Moreover, other type of equipment could be made with the laminated panel  20 , such as sports gear of all kinds (e.g., goalie equipment for hockey), casings of different equipment and the like. For instance, the laminated panel  20  may be used as part of snowshoes. The laminated panel  20  may form the decking, with the patterns  30 A being the central exposed part of the decking. The backing layer portion  30 B is hidden behind a peripheral eyelet strip by which the decking of laminated panel  20  is secured to the frame of the snowshoe. 
     Referring to  FIGS. 3A and 3B , there is illustrated a second embodiment of the laminated panel  20 . The laminated panel  20  of  FIGS. 3A and 3B  is of similar construction as the laminated panel  20  of  FIG. 2 , whereby like elements will bear like reference numerals. The laminated panel  20  of  FIGS. 3A and 3B  has additional components in a periphery cover layer portion  42 , with cutouts  42 A and  42 B, and see-through protective layer portion  43  (shown as a pair of pieces). 
     The see-through protective layer portion  43  is made of a transparent or translucent material, allowing the visual exposure of the material of the patterns  30 A. Therefore, the layer  43  is sized to cover the patterns  30 A. According to an embodiment, the material used for the protective layer portion  43  is a fusible polymeric material, such as Surlyn™, that is compatible with the backing layer portion  30 B, for the periphery of the layer portion  43  to fuse with the backing layer portion  30 B, and therefore conceal the material of the patterns  30 A thereunder. Any suitable thickness of the fusible polymeric material may be used for the protective layer portion  43  (e.g., 0.010″). 
     The periphery cover layer portion  42  is used to protect the edges of the patterns  30 A, considering the woven nature of the material of patterns  30 A in some embodiments. Therefore, the periphery cover layer portion  42  has the cutouts  42 A and  42 B sized such that the layer portion  42  covers the periphery of the patterns  30 A. Therefore, the cutouts  42 A and  42 B have any appropriate ornamental shape to create the desired visual effect. 
     The periphery cover layer portion  42  is therefore made of an opaque material that is compatible with the protective layer portion  43  and with the backing layer portion  30 B for fusing to one another and therefore protect the material of the patterns  30 A. For instance, a fusible polymeric material, such as Surlyn™, may be used for the periphery cover layer portion  42 . For this reason, the outer periphery of the layer portion  42  is substantially smaller than that of the backing layer portion  30 B, as the backing layer portion  30 B need not have a presentable finish as it will be behind components of the boot or other accessory made from the laminated panel  20 . 
     As a result, the edges of the patterns  30 A are covered by the periphery cover layer portion  42 , while the main surface of the patterns  30 A are covered by the see-through protective layer portion  43 . This reduces the delamination or garneting of the material of the patterns  30 A. Moreover, these layer portions may reduce water penetration in the laminated panel  20  via the material of the patterns  30 A.