US 12,466,108 B2
Methods of forming bevels in flooring planks
Jerry Yang, Shanghai (CN); Felix J. Herrera, Hanoi (VN); and Bryant Nie, JiaXing (CN)
Assigned to Shaw Industries Group, Inc., Dalton, GA (US)
Appl. No. 18/881,173
Filed by Shaw Industries Group, Inc., Dalton, GA (US)
PCT Filed Jun. 28, 2024, PCT No. PCT/US2024/036082
§ 371(c)(1), (2) Date Jan. 3, 2025,
PCT Pub. No. WO2025/006931, PCT Pub. Date Jan. 2, 2025.
Claims priority of provisional application 63/523,789, filed on Jun. 28, 2023.
Prior Publication US 2025/0170753 A1, May 29, 2025
Int. Cl. B28B 7/26 (2006.01); B28B 3/04 (2006.01)
CPC B28B 7/26 (2013.01) [B28B 3/04 (2013.01)] 22 Claims
OG exemplary drawing
 
1. A method for forming a core layer for a flooring plank having one or more beveled edges, the method comprising:
(a) depositing an uncured binder material into a tray;
(b) placing a patterned plate over the uncured binder material in the tray, the patterned plate having a pattern of bevels that extend into a surface of the uncured binder material when the patterned plate is placed over the tray;
(c) adding the tray and patterned plate onto a stack of one or more trays, wherein each tray in the stack comprises uncured binder material and has a corresponding patterned plate;
(d) applying a pressure to the stack of trays as the uncured binder material is in the process of curing in each of the trays in the stack;
(e) removing the applied pressure from the stack of trays;
(f) separating a board of cured binder material from each tray in the stack, wherein each board has the pattern of bevels formed on a surface of the board, and wherein the pattern of bevels corresponds to one or more flooring planks; and
(g) cutting each board of cured binder material along the pattern of bevels to create a core layer for one or more flooring planks.