US 12,263,627 B2
Sloped edge on decorative articles with a rigid base and a decor that is digitally printed thereon
Dale Carson Granberry, Chattanooga, TN (US)
Assigned to Shaw Industries Group, Inc., Dalton, GA (US)
Appl. No. 18/695,149
Filed by Shaw Industries Group, Inc., Dalton, GA (US)
PCT Filed Jul. 28, 2023, PCT No. PCT/US2023/029013
§ 371(c)(1), (2) Date Mar. 25, 2024,
PCT Pub. No. WO2024/026112, PCT Pub. Date Feb. 1, 2024.
Claims priority of provisional application 63/399,487, filed on Aug. 19, 2022.
Claims priority of provisional application 63/393,799, filed on Jul. 29, 2022.
Prior Publication US 2024/0335995 A1, Oct. 10, 2024
Int. Cl. B29C 48/00 (2019.01); B29C 48/07 (2019.01); B29K 105/06 (2006.01); B29K 309/00 (2006.01); B29L 7/00 (2006.01); E04B 5/43 (2006.01); E04F 15/02 (2006.01); E04F 15/10 (2006.01)
CPC B29C 48/0022 (2019.02) [B29C 48/0023 (2019.02); B29C 48/022 (2019.02); B29C 48/07 (2019.02); E04B 5/43 (2013.01); E04F 15/02033 (2013.01); E04F 15/102 (2013.01); B29K 2105/06 (2013.01); B29K 2309/14 (2013.01); B29L 2007/002 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method of manufacturing angled edges on decorative articles, the method comprising:
extruding a sheet of core material;
cutting the sheet of core material into a slab;
cooling the slab;
after the slab has been cooled down to at least a predetermined temperature, wherein the predetermined temperature is less than or equal to 150 degrees Fahrenheit, cutting one or more angled edges on a top surface of the slab;
rotating the slab;
cutting one or more additional angled edges on the top surface of the rotated slab such that the one or more additional angled edges intersect the one or more angled edges previously cut on the top surface of the slab;
digitally printing a décor layer on the top surface of the slab after cutting the one or more angled edges and the one or more additional angled edges on the top surface of the slab;
applying a wear layer over the digitally printed décor layer; and
cutting the slab into a plurality of decorative articles, where each decorative article has one or more outer edges that are angled.