Patent Publication Number: US-2013251934-A1

Title: Ornamented substrate and methods for forming the same

Description:
FIELD 
     This invention relates to a product and method for inlaying an ornament into a substrate, such as, for example, but not limited to, floorboards, trim and crown moldings in a home, office or commercial establishment. 
     INTRODUCTION 
     Celebrities and wealthy individuals have popularized the inlaying of precious gemstones such as crystals, diamonds and rubies into common articles such as handbags, watches and even cellular phones. Manufacturers now offer less expensive products ornamented with replica gems (such as cubic zirconia) which emulate the more expensive products with authentic precious gems. However, there exists a need for a product and method for ornamenting substrates, such as, for example, but not limited to, floorboards, trim and crown moldings in a home, office or commercial establishment. 
     SUMMARY 
     This invention relates to a product and method for inlaying an ornament into a substrate, such as, for example, but not limited to, floorboards, trim and crown moldings in a home, office or commercial establishment. 
     In particular, a method for inlaying an ornament having one or more gems into a substrate is shown. The method includes forming a cavity within a portion of a surface of the substrate and securing an ornament in the cavity. 
     The method further includes after securing the ornament in the cavity, sealing the cavity with a substantially transparent cover. 
     Further, the ornament can be secured in the cavity so that no portion thereof protrudes beyond the portion of the surface of the substrate. 
     Moreover, after sealing the cavity with the substantially transparent cover, the cover can be flush with the surface of the substrate. 
     Further, sealing the cavity with the substantially transparent cover includes laying the cover in the cavity above the ornament and forcing the cover towards the ornament until the opposing face of the cover is flush with the surface of the substrate. Further, a sealant can be applied between the cover and the surface of the substrate. 
     The ornament can be secured inside the cavity by, for example, but not limited to, friction fitting the ornament inside the recess or bonding the ornament in the cavity with an adhesive. 
     The ornament can be formed by bonding the one or more gems to a second substrate prior to securing the ornament in the cavity. 
     Further, an interior surface of the cavity can be colored prior to securing the ornament inside the cavity. 
     The second substrate can be selected from the group consisting of mesh and fabric. 
     The substrate can be, for example, but not limited to, a floorboard or crown molding. 
     In addition, lighting can be inserted in the cavity. 
     Applicants&#39; teachings also include an ornamented substrate where the substrate includes a cavity extending along a surface of the substrate and an ornament having one or more gems, and the cavity is sized to receive the ornament and the ornament is secured in the cavity. 
     In particular, the ornamented substrate has a substantially transparent cover in the cavity overlaying the ornament. The substantially transparent cover can be flush with the surface of the substrate. 
     Moreover, a sealant can be provided between the cover and the surface of the substrate. 
     Further, the ornament can be friction fitted inside the cavity. 
     Moreover, a second substrate can be provided between the one or more gems and the cavity of the substrate. The second substrate can be selected from the group consisting of mesh and fabric. 
     Further, the ornamented substrate can have lighting received in the cavity. 
    
    
     
       DRAWINGS 
       Embodiments of the invention may be understood by reference to the following detailed description when read with the accompanied drawings in which: 
         FIG. 1   a  is a partially exploded view of an ornamented wooden substrate, in accordance with some embodiments of the invention; 
         FIG. 1   b  is an ornamented substrate, in accordance with some embodiments of the invention; 
         FIG. 1   c  is an ornamented substrate, in accordance with some embodiments of the invention and 
         FIG. 2  is a method for inlaying an ornament into a wooden substrate, in accordance with some embodiments of the invention. 
     
    
    
     DESCRIPTION OF VARIOUS EMBODIMENTS 
       FIG. 1  is a partially exploded view of an ornamented substrate  10  in accordance with some embodiments of the invention. In the example shown, ornamented substrate  10  is an ornamented floorboard. As shown, substrate  10  includes wooden substrate  12 , cavities  14 ,  16  and ornaments  18 ,  20 . 
     As used herein and in the claims, the term substrate refers to both substrates made of wood, for example, hardwood, as well as substrates made from processed or simulated wood. For example, as used herein, a “wooden” substrate may refer to substrates made of solid wood (e.g., oak or pine), plywood, particle board, laminates (e.g., a combination of a melamine resin, a photographic applique and a clear protective layer), or synthetic fiber boards. 
     In the example shown, wooden substrate  12  is a laminate floorboard comprising a clear coat  22 , a photographic applique  24  and a melamine resin layer  26 . Preferably, photographic applique  24  gives wooden substrate  12  the appearance of a hardwood floorboard when viewed through clear coat  22 . Alternatively, however, photographic applique  24  may provide any suitable appearance. 
     As shown, wooden substrate  12  includes a tongue  28  and a groove  30  which facilitate tongue-and-groove connections with adjacent floorboards. Alternatively, however, wooden substrate  12  may be configured to connect with adjacent floorboards in any suitable way. 
     In the example shown, wooden substrate  12  is planar and includes a flat outer surface  32 . However, in some embodiments, wooden substrate  12  may not be planar and outer surface  32  may not be flat. For example, it is explicitly contemplated that wooden substrate  12  may be crown molding or trim which curves about the perimeter of an archway, and outer surface  32  may be curved according to a design pattern. 
     In the example shown, wooden substrate  12  includes two cavities  14 ,  16 . Alternatively, however, wooden substrate  12  may include just one cavity, for example, but not limited to, a longitudinal channel or recess, or more than two cavities. Each cavity may be sized and shaped for receiving one or more ornaments. In the example shown, cavity  14  is configured to receive ornament  18  and cavity  16  is configured to receive ornament  20 . Cavities and ornaments may be configured with any desired shape. For example, cavity  14  has a square cross-section whereas cavity  16  has an irregular cross-section resembling the letter “M”. 
     In some embodiments, a cavity may be sized to frictionally engage with an ornament received therein. For example, cavity  14  may have cross-sectional dimensions that are fractionally smaller than those of corresponding ornament  18 . Thus, when ornament  18  is received in cavity  14  it may frictionally engage with (and perhaps elastically or plastically deform) inside walls  34  of cavity  14 . Thus ornament  18  may be secured within cavity  14  by a friction fit without the use of adhesives or other mechanical fastenings. In other embodiments, adhesives, such as, for example, but not limited to, Hotfix adhesive, a clear silicone or bonding glue, or other mechanical fastenings may be used to secure an ornament inside a cavity. 
     In the example shown, cavity  16  and ornament  20  are irregularly shaped. Therefore, it may be more difficult to configure cavity  16  to produce a friction fit with ornament  20  when ornament  20  is received inside cavity  16 . Thus, according to some embodiments, ornament  20  may be secured inside cavity  16  using adhesives, such as, for example, but not limited to, Hotfix adhesive, a clear silicone or bonding glue, or other mechanical fasteners such as nails, staples, or screws for example. 
     In some embodiments, the coloration of the inside walls of a cavity may substantially differ from the outer surface of a wooden substrate. In the example shown, wooden substrate  12  is a laminate floorboard including clear coat  22 , photographic applique  24  and melamine layer  26 . Where a cavity extends from outer surface  32  through photographic applique  24 , inside walls  34  of the cavity will not have the benefit of the photographic applique when viewed from the outside. Accordingly, it may be desirable to paint, stain or otherwise alter the appearance of the inside walls  34  of the cavity to match or compliment the outer surface  32  or the ornament  18 . It may be especially desirable to do so where the inside walls of the cavity can be seen through ornament when received therein. 
     In another example, the wooden substrate may be a stained hardwood floorboard. If the stain does not penetrate as deeply as the cavity, then the interior walls of the cavity may not match the outer surface of the wooden substrate and thus it may be desirable to color, stain or otherwise alter the appearance of the inside walls of the cavity to match or compliment the outer surface of the wooden substrate and/or the ornament to be received in the cavity. 
     However, it is contemplated that in other embodiments the appearance of the inside walls of a cavity may be left unaltered, even though the appearance of the inside walls differs from the appearance of the outer surface and even though the inside walls can be seen through the ornament inserted therein. 
     In the example shown ornament  18  includes one gem  36  and ornament  20  includes a plurality of gems  37  above a second substrate  38 . In other embodiments, an ornament may include any number of gems arranged in any configuration. 
     As used herein, the term “gem” refers to precious and semi-precious gemstones, such as crystals, diamonds, rubies, emeralds etc. as well as real and artificial stones that resemble or emulate precious and semi-precious gemstones such as cubic zirconia (a diamond simulant composed of zirconium oxide) and moissanite for example. 
     Some ornaments may include a substrate, such as second substrate  38  of ornament  20 . The second substrate may be fitted within cavity  16  and, in some examples, may be bonded within cavity  16  using an adhesive, such as, for example, but not limited to, Hotfix adhesive, a clear silicone or bonding glue. Gems  37  may be bonded to second substrate  38  to keep gems  37  securely arranged during and after insertion into cavity  16 . The gem stones may be bonded to the second substrate using an adhesive, such as, for example, but not limited to, Hotfix adhesive, a clear silicone or bonding glue. The second substrate  38  may be first placed within the cavity  16  and then the gems  37  placed on the second substrate  38 . Alternatively, the gems  37  may be first secured to the second substrate  38 , and then the second substrate  38  is placed within the cavity  16 . The second substrate  38  may be composed of any suitable material, for example, but not limited to, second substrate  38  may comprise a fabric material such as felt, velvet or silk; a transparent material such as a clear plastic sheet; or an open mesh. 
     The second substrate  38  may be used in addition to or instead of coloring the inside walls of a cavity. For example, a black velvet substrate may conceal the appearance of the inside walls of a cavity and emphasize the glitter of the gems. 
     In the example shown, second substrate  38  of ornament  20  is sized to cover substantially the entire surface of inside walls  34  of cavity  16 . However, in alternative embodiments, second substrate  38  may be sized to cover less than the entire surface of the inside walls of a cavity. Similarly, ornament  20  is shown including gems  37  which cover substantially the entire surface area of second substrate  38 . In alternative embodiments, the gems of an ornament may cover less than or more than the surface area of the second substrate  38 . 
     Preferably, ornaments  18 ,  20  do not extend beyond the outer surface  32  of the wooden substrate  12  when inserted into cavities  14 ,  16  (e.g., protrude above surface  32  when the wooden substrate  12  is used in a floor). This may advantageously lessen the occurrence of objects interfering with, catching on or dislodging the ornaments  18 ,  20  when they move across ornamented wooden substrate  12 . For example, recessing ornaments  18 ,  20  including gems  36 ,  37  beneath the outer surface  32  may prevent gems  36 ,  37  from being dislodged by the sliding of furniture across ornamented wooden floorboard  10 . 
     However, in other embodiments, the ornaments  18 ,  20  may extend beyond the outer surface  32 . For example, in the case of an ornamented crown molding or trim for a doorway, there may be less concern of gems being interfered with and thus it may be more appropriate to have the ornament extend beyond the outer surface of the wooden substrate. 
     In some embodiments, where the ornament does not extend beyond the outer surface of the wooden substrate, a substantially transparent cover such as a polycarbonate sheet (for example, Lexan™) may overlay the ornament. In the example shown, a cover  40  is configured to overlay ornament  20  when received in cavity  16 . Cover  40  may be secured within cavity  16  using an adhesive, such as, for example, but not limited to, Hotfix adhesive, a clear silicone or bonding glue. Preferably, cover  40  is configured to be flush with the outer surface  32  once received inside cavity  16 . Where outer surface  32  is not flat and planar, cover  40  may be shaped to emulate or compliment the design of outer surface  32 . Alternatively, outer surface  32  may be flat and planar despite the shape of outer surface  32 . 
     Preferably, after cover  40  has been inserted into cavity  16 , the cracks between cover  40  and outer surface  32  along the perimeter of cavity  16  are sealed with a sealant such as, for example, but not limited to, a silicon sealant. Alternatively, however, the cracks may be left unsealed. 
       FIG. 1   b  shows another example of an ornamented substrate  40 , in accordance with some embodiments of the invention. In the example shown, ornamented substrate  40  includes a substrate  42  ornamented with ornament  44 . Substrate  42  may be, for example, trim for a door way. As shown, ornament  44  comprising crystals  46  is received in cavity  48  formed within a portion of surface  50  of substrate  42 . 
     In the example shown, cavity  48  comprises a longitudinal channel. In some embodiments, cavity  48  may extend to a longitudinal edge  52  (as shown in  FIG. 1   b ). This may permit the cavity  48  and ornament  44  to intersect with a complimentary cavity and ornament of another ornamented substrate, thereby forming a contiguous pattern of ornaments. 
       FIG. 1   c  shows a partially exploded view of another example of an ornamented substrate  60 , in accordance with some embodiments of the invention. In the example shown, ornamented substrate  60  comprises substrate  62 , lighting  64  and ornament  66 . Lighting  64  and ornament  66  are configured to be received in a cavity  68  of substrate  62 . Lighting  64  may be configured to be received in cavity  68 . In some embodiments, cavity  68  may comprise pockets  69  configured to receive lighting  64 . 
     Lighting  64  may comprise lights  80  and one or more power cables  72 . Lights  80  may be, for example, LED lights, halogen lights, or incandescent lights. A passage  70  may be provided in substrate  63  to provide a path for power cables  72  of lighting  64  to a power source (not shown) such as a power outlet or a battery, for example. 
     in the example shown, ornament  66  includes a second substrate  74  and gems  76 . Optionally, second substrate  74  may include openings  78  which align with the lights  80  of the lighting  64 . This may permit light from lighting  64  to shine through second substrate  74  even if second substrate  74  is opaque. Alternatively, second substrate  74  may not include openings  78 . For example, second substrate  74  may be transparent or translucent and light from lighting  64  may shine through the material of second substrate  74 . 
     Referring now to  FIG. 2 , there is shown method for inlaying an ornament into a wooden substrate, in accordance with some embodiments of the invention. 
     At  210 , an ornament is optionally formed. For example, where an ornament comprises a plurality of gems and a second substrate, this may comprise adhering or otherwise securing the gems to the second substrate. In some embodiments, it is not necessary to form an ornament. For example, it may not be necessary to form an ornament when the ornament comprises a single gem. 
     At  212 , the cavity (for example, a recess) is formed. Forming the cavity may be performed before or after forming the ornament. Forming the cavity may comprise chiseling, machining, cutting, or otherwise removing material from the wooden substrate to create a cavity. Preferably, the cavity should not protrude right through the wooden substrate so as to create a through-hole. In some embodiments, however, a portion of the cavity may form a through-hole in the wooden substrate. 
     At  214 , the cavity is optionally colored. For example, the cavity may be painted, stained, or lined with a colored material. In some embodiment, the cavity may not be colored. For example, after forming the cavity, the cavity may already have a suitable color, or the ornament to be received in the recess may include a suitably opaque substrate which can obscure the view of the inside walls of the cavity. 
     At  216 , the ornament is secured in the cavity. In some embodiments, the ornament may be secured inside the cavity by a friction fit. In other embodiments, adhesives and/or mechanical fasteners may be used to secure the ornament inside the cavity. In embodiments where the ornament includes a second substrate, it may be sufficient to glue, staple, nail or screw the second substrate to the cavity either before or after gems are secured to the second substrate. 
     At  218 , the cavity is optionally sealed. Sealing the cavity may comprise overlaying a cover sheet of substantially transparent material over the ornament inside the cavity. The cover may be configured to lay flush with the outer surface of the wooden substrate after insertion. A sealant such as a silicone sealant may be used to seal the cracks that remain between the cover and the outer surface of the wooden substrate along the perimeter of the cavity. 
     In some embodiments, the cavity may not be sealed. For example, the cavity may be left unsealed where there is little concern that the ornament inside the cavity will be interfered with. For example, an ornamented crown molding or trim around a doorway or along the upper edge of a wall may be left unsealed. 
     The invention has been described with regard to a number of embodiments. However, it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.