Abstract:
A method for manufacturing a baseboard with a decorative pattern along its top edge. A decorative pattern is first designed using Computer Aided Drafting (CAD) software that encapsulates the decorative pattern and is subsequently saved to a computer file that is readable by the CAD software. The CAD software file is then converted into a sequence of codes, normally G-Code, using a software conversion utility and the resulting sequence of codes is then loaded into a Computer Numeric Controller (CNC) machine. Wood material to be used in producing the baseboard(s) is placed onto the CNC machine and the CNC machine&#39;s numeric controller then executes the previously loaded sequence of codes to produce one or more baseboards with a decorative pattern along its top edge from the wood material loaded onto the CNC machine.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to wall structures, and in particular, baseboards or wall bases. The invention relates more specifically to a method for cutting a pattern along the top edge of a baseboard. This method substantially improves the appearance of baseboard by cutting a pattern containing hearts, waves, animals, and others, along the top edge of the baseboard so as to complement the decor of the room. 
         [0003]    2. Description of the Related Art 
         [0004]    Many individuals derive a sense of pride when utilizing baseboards as part of the decor of a room within their home. Baseboards serve multiple purposes when added to a room. First baseboards disguise or conceal imperfections at the junction of the flooring and the upstanding walls of the room. Second baseboards protect the lower portion of the wall from impact by furniture, shoes, and appliances such as vacuums or carpet cleaners. Third the installation of baseboards within a room provide that room with a finished look as edges are softened. Finally, the most important purpose of a baseboard is to add to the room&#39;s decor. 
         [0005]    Baseboards come in a variety of different decorative effects however the means of applying a decorative effect to a baseboard comprised of wood or wood fibers are basically limited to two approaches. 
         [0006]    The first approach is to use a baseboard with multiple components. The key component is a generic baseboard with certain features, such as cutouts, that allow for the addition of other components that provide the decorative effect. US patent publication 2005/0257485 teaches a baseboard with a decorative front surface that also contains a horizontal groove for accepting a decorative filler strip of different sizes and shapes. U.S. Pat. No. 7,168,474 teaches a baseboard with a front surface that may accommodate one or more interchangeable decorative modules. However these approaches do not teach a means to decorate the top edge of a baseboard and as such the top edge of the baseboard as taught remains a simple linear surface. 
         [0007]    The second approach makes use of wood molding machinery that applies a decorative pattern to the front of a baseboard by pressing the pattern onto the front surface of the baseboard. International patent publication WO 98/48992 teaches a means whereby wood fiber boards, known in the art as medium density fiberboard or MDF, are taken through a process whereby they are softened by a combination of heat and moisture and then passed into a molding chamber where a decorative pattern is pressed onto the front surface of the MDF and then subsequently the MDF is cut into strips according to the boundaries of the pressed decorative patterns. U.S. Pat. No. 7,195,686 teaches a process similar to that described by WO 98/48992 and adds to it additional layers of material to the base material comprised of MDF, such as a veneer layer of a wood product, that are bonded together by a pressing operation. However these approaches do not teach a method to decorate to top edge of a baseboard with a pattern and as such the top edge of the baseboard as taught remains a simple linear surface. 
         [0008]    The approaches described above teach how to apply a decorative pattern to the front surface of a baseboard but do not teach how to apply a decorative pattern to the top edge of a baseboard. Although baseboards with a decorative front surface are commonly used to finish a room it may be desirable install baseboards with a decorative top edge containing patterns of hearts, waves, or animals. However a method to fabricate a baseboard with a decorative top edge has not been disclosed by the prior art. 
         [0009]    In light of the above, it is an object of the present invention to provide a method for applying a decorative pattern to the top edge of multiple baseboards that may be formed from a single sheet of MDF that is typically 4 feet by 8 feet and ½ to ¾ inches thick. 
         [0010]    It is yet a further object of the present invention to provide a method for machining a decorative pattern to the top edge of a baseboard that may be formed from a board natural wood that is typically 6 inches by 8 feet and ½ to ¾ inches thick. 
         [0011]    Yet another object of the present invention is to provide a method for manually applying and cutting a decorative pattern to the top edge of a baseboard using a woodworking router. 
       BRIEF SUMMARY OF THE INVENTION 
       [0012]    The present invention discloses various method embodiments for applying a decorative pattern along the top edge of a baseboard that was lacking in the prior art. 
         [0013]    In the preferred embodiment the decorative patterns will first be designed using Computer Aided Drafting (CAD) software. The design will be such that the patterns will repeat on the boundary of the wood material that is to be used in fabricating the baseboard so that when the individual baseboards are joined end to end the decorative pattern will not be interrupted. Once the design has been completed the CAD file will need to be converted into a format that is readable by a Computer Numerically Controlled (CNC) wood router machine hereafter referred to simply as a CNC machine. A CNC machine contains a larger flat surface, hereafter referred to as the table, whereon the wood material to be cut is placed, a means for securing the wood on the table, a moveable head containing a cutting tool that operates in three axises over the flat surface and engages the cutting tool with the wood material, and a computer that reads a computer file containing a set of programming instructions for the movement and travel speed of the head along any of the three axises: length, width, and height; the selection of the cutting tool to be used on the wood material; and the rotational speed of the cutting tool mounted to the head. A sheet of the wood material to be cut upon by the CNC machine is then placed on the flat surface of the CNC machine and secured either by a vacuum seal or by rollers that pin the wood material to the flat surface where it may be operably engaged by the cutting tool. The CAD converted file containing the programming instructions that are readable by the CNC machine is then read by the CNC machine whereupon the pattern depicted in the CAD file is cut onto the wood material forming one or more baseboards with a decorative pattern present along its top edge. 
         [0014]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
         [0015]    Neither this summary nor the following detailed description defines or limits the invention. The invention is defined by the claims. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0016]    The present invention will become more fully understood from the detailed description and accompanying drawings, wherein: 
           [0017]      FIG. 1  is a perspective view of a CNC machine that implements a vacuum pump system to secure the wood material. 
           [0018]      FIG. 2  is a side view of a CNC machine that implements a roller hold down system to secure the wood material. 
           [0019]      FIG. 3  shows a sample CAD drawing containing 8 baseboards to be made from one 4 feet by 8 feet sheet of MDF material, a sample listing of G-Code used by CNC machines, and a process to convert the CAD drawing to G-Code. 
           [0020]      FIG. 4  shows the method of the preferred embodiment of the present invention. 
           [0021]      FIG. 5  shows the method of a secondary embodiment of the present invention. 
           [0022]      FIG. 6  shows the method of another secondary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    The following descriptions of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0024]      FIG. 1  is a perspective view of CNC machine  10  that implements a vacuum pump system to secure the wood material that is to be worked upon. Many details have been removed so as to focus on the primary components. The largest single component of CNC machine  10  is table  12 . The purpose of table  12  is to provide a surface area to receive wood material that is to be worked on by CNC machine  10 . By providing a large surface area table  12  may accommodate larger sheets of wood material so as to allow a greater number of baseboards to be created simultaneously. To quickly and easily secure the wood material to table  12  CNC machine  10  uses vacuum pump  14  to create a pressure differential between the table and the wood material and securely, but not permanently, hold the wood material while it is being worked on. If the wood material does not cover the width of table  12  then vacuum valves  16  may be individually adjusted so as to properly secure the wood material on table  12  without undue effort by vacuum pump  14 . Lengthwise along table  12  on either side are guide rails  18 . In  FIG. 1  only one of the two guide rails  18  are visible. Guide rails  18  support the movement of gantry mounts  20  along the length of table  12  by the use of computer controlled electric motors thus providing one of the axes of movement, the X axis, for router  26 . Gantry mounts  20  support gantry  22  and allows gantry  22  to move over the entire length of table  12 . Gantry  22  contains one or more computer controlled electric motors that allow for the travel of router mount  24  along the length of gantry  22  providing a second axis of movement, the Y axis, for router  26 . Router mount  24  supports router  26  and contains one or more computer controlled electric motors so as to move router  26  along a path that is perpendicular to table  12  providing a third axis of movement, the Z axis, for router  26 . All of the electric motors and router  26  are controlled by numeric controller  28  which when activated begins to sequentially execute a set of instructions that was received from a computer which is not shown in  FIG. 1 . 
         [0025]    An operator of CNC machine  10  typically would first load numeric controller  28  with the desired set of instructions, then place the sheet of wood material to be cut according to the loaded instructions on table  12 , adjust vacuum valves  16  as required by the size of the sheet of wood material, engage vacuum pump  14  so as to secure the wood material being worked on, and finally activate numeric controller  28  to initiate the execution of previously loaded set of instructions. Numeric controller  28  will then activate the various motors to move router  26  to the desired location, and appropriately energize router  26  to commence the cutting operations contained in the instructions. 
         [0026]      FIG. 2  shows a side view of CNC machine  30  that is similar in every aspect to CNC machine  10  but for that fact that CNC machine  30  implements a roller hold down system to secure the wood material that is to he worked upon as opposed to CNC machine&#39;s  10  vacuum system. Many details have been removed so as to focus on the primary components. The largest single component of CNC machine  30  is table  32 . The purpose of table  32  is to provide a surface area to receive wood material that is to be worked on by CNC machine  30 . By providing a large surface area table  32  may accommodate larger sheets of wood material may be worked on so as to allow a greater number of baseboards to be created simultaneously. To quickly and easily secure the wood material to table  32  CNC machine  30  uses hold down rollers  34 , positioned on either side of router  40 , to clamp the wood material to table  32  while it is being worked on. Hold down rollers  34  operate with equal effectiveness on wood material of different widths so as to enable CNC machine  30  to cut wood material made of natural wood that is 6 inches in width to wood material made of MDF and is 48 inches in width. Lengthwise along table  32  on either side are guide rails, not visible in this view, that support the movement of gantry mounts  35  along the length of table  12  by the use of computer controlled electric motors thus providing one of the axes of movement, the X axis, for router  40 . Gantry mounts  35  support gantry  36  and allows gantry  36  to move over the entire length of table  32 . Gantry  36  contains one or more computer controlled electric motors that allow for the travel of router mount  38  along the length of gantry  36  over the width of table  32  providing a second axis of movement, the Y axis, for router  40 . Router mount  38  supports router  40  and contains one or more computer controlled electric motors so as to move router  40  along a path that is perpendicular to table  32  providing a third axis of movement, the Z axis, for router  40 . All of the electric motors are controlled by numeric controller  42  which when activated begins to sequentially execute a set of instructions that was received from a computer which is not shown in  FIG. 2 . 
         [0027]    An operator of CNC machine  30  typically would first load numeric controller  42  with the desired set of instructions, then place the sheet of wood material to be cut according to the loaded instructions on table  32 , adjust hold down rollers  34  as required by the size of the sheet of wood material so as to secure the wood material being worked on, and finally activate numeric controller  42  to initiate the execution of the previously loaded set of instructions. Numeric controller  42  will then activate the various motors to move router  40  to the desired location, and appropriately energize router  40  to commence the cutting operations contained in the instructions. 
         [0028]      FIG. 3  shows CAD drawing  44  of a single sheet of MDF that is sized at 4 feet by 8 feet containing designs for 8 baseboards with a different decorative pattern along the top edge of each baseboard. CAD drawings may contain different decorative patterns on baseboards to be created or the pattern may be identical across all of the baseboards. Additionally the design may be for other shapes and sizes of wood material such as a single board that is 6 inches in width and 8 feet in length. There are many different CAD software programs that may be used but it is common for the file created from CAD programs to be in the Data Exchange Format (DXF) popularized by the CAD software AutoCAD®. However CNC machines are not able to read and understand information in a DXF file and alternatively use a set of codes, referred to as “G-Codes”, for use in controlling the various electrical motors used to guide the router along the X (length), Y (width), and Z (height) axises. A representative portion of a sample listing of G-Code codes is shown as G-Code listing  46 . To convert CAD drawing  44  to G-Code listing  46  conversion utility  48  must be used. Conversion utility  48  will analyze CAD drawing  44  and create G-Code listing  46  that when loaded into CNC machine&#39;s numeric controller and executed will result in the design in CAD drawing  44  to be cut into the MDF sheet and from the one MDF sheet 8 baseboards containing a decorative pattern along its top edge are created. 
         [0029]      FIG. 4  shows the method of preferred embodiment  50 . In step  52  a design of the decorative pattern to be used on the top edge of a baseboard is created using CAD software. There are many limitations on the design such as the height of a baseboard is typically less than six inches, the decorative pattern should withstand robust handling so that elements within the pattern are not susceptible to breakage, the decorative pattern repeats on a interval that is a common factor of the length of the wood material to be used so that the decorative pattern will restart itself when baseboards are connected end to end, and more. In step  54  the decorative pattern designed in step  52  is saved as a CAD file that is typically in the DXF format or some other format that is readable by a G-Code conversion utility program. Step  56  will convert the CAD file created in step  54  into a sequence of G-Codes that may be executed by numeric controllers in CNC machines. In step  58  the G-Codes created in step  56  are loaded into the CNC machine. In step  60  the wood material to be used in making the baseboard is placed on the CNC machine&#39;s table and secured to prevent movement while being worked on by the CNC machine&#39;s router. Now that the G-Code instructions have been loaded into the numeric controller and the wood material is ready to be worked on step  62  will engage the numeric controller to execute the instructions and cut the decorative pattern along the p edge of the baseboard in accordance with the design conceived of in step  52 . Step  58  may be performed in parallel with step  60 . 
         [0030]    Since G-Codes are difficult to program and require skills that are beyond those skills necessary to create CAD files the preferred embodiment shown in  FIG. 4  is appealing as it eliminates the need to have the skills required to create G-Code as the conversion process described in step  56  perform this task. This embodiment will also work with CNC machines using either vacuum system or hold down rollers and with wood materials using MDF sheets or boards of natural wood. 
         [0031]      FIG. 5  shows the method of secondary embodiment  70 . In step  72  a design of the decorative pattern to be used on the top edge of a base is created. There are many limitations on the design such as the height of a baseboard is typically less than six inches, the decorative pattern should withstand robust handling so that elements within the pattern are not susceptible to breakage, the decorative pattern repeats on a interval that is a common factor of the length of the wood material to be used so that the decorative pattern will restart itself when baseboards are connected end to end, and more. In contrast with preferred embodiment  50 , secondary embodiment  70  will encode the design created in step  72  directly into a sequence of G-Codes that may be executed by numeric controllers in CNC machines in step  72 . In step  76  the G-Codes created in step  74  are loaded into the CNC machine. In step  78  the wood material to be used in making the baseboard is placed on the CNC machine&#39;s table and secured to prevent movement while being worked on by the CNC machine&#39;s router. Now that the G-Code instructions have been loaded into the numeric controller and the wood material is ready to be worked on step  80  will engage the numeric controller to execute the G-Code instructions that have been loaded and cut the decorative pattern along the top edge of the baseboard in accordance with the design conceived of in step  72 . Step  76  may be performed in parallel with step  78 . 
         [0032]    Although embodiment  70  requires the skills of a CNC machinist who is versant in G-Code there is the advantage of a greater level of control over the G-Code that is loaded into the numeric controller. In embodiment  50  the G-Code is created by a software application that understands the structure of a CAD file and can properly create the G-Code that implements the design contained in the CAD file. As such embodiment  50  is bounded by any inefficiencies in the G-Code that is created in step  56 . In embodiment  70  the machinist may overcome any inefficiencies when creating the G-Code. As a result the cutting of baseboards in embodiment  70  may take less time than the cutting of baseboards in embodiment  50 . 
         [0033]      FIG. 6  shows the method of another secondary embodiment  90 . In this embodiment a baseboard created from embodiment  50  or  70  is to be used as a guide tool for creating new baseboards. In step  92  the wood material to be used is secured to a table surface. In step  94  the guide tool is positioned and secured to the wood material by any number of means. In step  96  a hand held router tool is then moved along the edge of the guide tool to create a new baseboard with the same decorative edge as the decorative edge present in the guide tool. 
         [0034]    Embodiment  90  has certain advantages and disadvantages over embodiments  50  and  70 . The primary advantage is that embodiment  90  does not use a CNC machine in any of its steps and as such it is a less expensive to implement than embodiments  50  and  70 . Another advantage is that it allows baseboards with a decorative top edge to be created outside the presence of CNC machines in situations where only a few additional baseboards are required to complete the job. 
         [0035]    The previous descriptions of the various embodiments is provided to enable any person skilled in the art to make and use the present invention. The various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of the inventive faculty. Thus, the present invention is not intended to be limited to the embodiments discussed herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.