Stock material or miscellaneous articles – Layer or component removable to expose adhesive
Reexamination Certificate
2001-05-02
2003-11-11
Ahmad, Nasser (Department: 1772)
Stock material or miscellaneous articles
Layer or component removable to expose adhesive
C052S741100, C052S741300, C052S745210, C052S747100, C156S071000, C312S140300, C312S140400, C428S041700, C428S041800
Reexamination Certificate
active
06645591
ABSTRACT:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
In the prior art, various methods have been employed for over the past fifty years to assemble components during the fabrication of countertops, etc. Specifically, these methods included the use of: dangerous, highly flammable, non-compliant VOC (Volatile Organic Compounds) emitting contact adhesives; reactivated hot-melt adhesives requiring the use of ovens or irons; PVA (polyvinyl alcohol) adhesives (i.e. white glue) requiring the use of clamps, masking tape, and other methods of holding components in place during the drying cycle; nails, screws, and staples requiring the use of hand tools or power tools; water-borne contact adhesives which have a long history of unreliability often resulting in delamination of components.
The patent to Ornstein, U.S. Pat. No. 3,295,474, shows a wall mounted shelf assembly. The shelf and its components are held into position by means of a form of adhesive backing sheet. This holds the various portions of the shelf in place. But, the adhesive is only used for holding the vertical brackets of the shelf in place, and which are basically secured into the position by means of the various shown screws.
The patent to McLaurin, U.S. Pat. No. 2,031,275, shows an adhesively coated sheet material. The purpose of the gummed sheet material, which may be used in the form of a gummed tape, is to facilitate veneering operations.
The patent to Baker, U.S. Pat. No. 2,815,252, shows a nylon glide strip. This patent simply discloses the application of a nylon strip, apparently to reduce friction between a supporting surface or guide, while the drawer slides thereover, and attaining such reduction in friction through the application of its taped slides.
The patent to Krantz, U.S. Pat. No. 3,413,678, shows the use of a carpet tape, which is a double-faced adhesive, for holding carpeting in place, as is well known.
The patent to Gregov, U.S. Pat. No. 3,869,106, shows the application of safety bumper for furniture, and this bumper is also applied by means of a form of coated adhesive, that holds the bumper in place, once secured to the edge of furniture.
The patent to Glickman, U.S. Pat. No. 3,915,528, shows the application of a desk attachment, in the form of a protective panel, that is held in position upon the design by means of an adhesive coating. The adhesive coating is revealed, upon tearing back of its backing sheet.
The patent to Smith, U.S. Pat. No. 3,922,408, shows a corner and edge protector cover, not too unlike that as previously described in the two recently reviewed patents. It simply shows a protector, which may include a porous foam material, and an inner surface adhesive, which is pressure sensitive, and when the peel strip is removed, allows the corner protector to be applied to a counter.
The patent to Rutz, U.S. Pat. No. 5,208,084, shows another type of edge pad. This device simply shows the use of an adhesive strip for holding the pad in place, as to the edge of a desk, table, or the like.
The patent to Wacker, U.S. Pat. No. 5,301,616, shows a repositionable paper stop for a table surface. This is a stop means applied to the top surface of a table, which may be a tiltable table, as can be seen.
The patent to Adams, U.S. Pat. No. 5,750,227, shows a tiled surface covering. The tiles are applied by means of pressure sensitive adhesive, to the underlay sheet, for providing means for holding the tiles in place, once applied.
These are examples of prior art devices, as disclosed in previous patents.
These methods have been used to assemble components and fabricate countertops, etc., by the following: factory and shop workers employed to assemble or fabricate these products in an industrial environment; contractors and installers who are required to perform these tasks in the field or on job-sites; Do-It-Yourselfers (DIYers) who attempt to perform these tasks in their homes and offices.
Specifically, the components used in the assembly or fabrication process include—but are not limited to: Laminate pieces (End Caps) which are applied to the ends of countertops, etc., to finish these ends creating an aesthetic appearance and sealing them from moisture and other penetrating agents; Laminate strips (Edge Banding) which are applied to the edges of countertops, etc., to finish these edges creating an aesthetic appearance and sealing them from moisture and other penetrating agents; Laminate sheet (Decking) which is applied to the surface of panels (usually some type of hardwood, plywood, pressed wood, particle board, or other composite material of some type) to create a functional, decorative surface; Blocks and strips of wood (Buildup), including hardwood, plywood, pressed wood, particle board, or other composite material of some type; Pieces of laminated wood (End Splashes) which are applied at the end of countertops, etc., to protect the wall or the cabinetry at the end of a countertop; Acrylic or polyester pieces and sheets (Solid Surface) which may be used as an alternate product to laminate previously described.
SUMMARY OF THE INVENTION
Present day concerns shared by all manufacturers in the business of fabricating countertops, etc., and by contractors and installers who are engaged in completing the assembly and fabrication of countertops, etc., while in the field or on the job-site include safety, regulatory compliance, quality, and labor efficiency.
Although this invention is simple, its benefits are extremely important to these groups. What is claimed as new is the manner in which this invention addresses these four issues.
It is one of the objects of this invention to improve safety by eliminating the need to use extremely flammable solvent-based contact adhesives during the assembly of end caps, edge banding, decking and buildup. In most fire protection districts the use of such adhesives requires expensive application booths or is banned entirely. In areas where fire safety inspections are not conducted or where restrictions are not enforced, the use of such adhesives often results in fires and explosions. Additionally, overspray and excessive adhesive can only be removed from laminate surfaces through the use of extremely flammable solvent cleaners containing toluene and MEK (methyl ethyl ketone).
Hot melt adhesives are also used to assemble components. Handling components coated with hot melt at a temperature often in excess of 250° F. exposes employees to serious burn risk, and in fact, numerous such incidents occur regularly. While other bonding agents are available to, these, too, have many significant inherent deficiencies and disadvantages.
Another object of this invention is to encourage and enable compliance with local and federal regulations regarding emissions and effluents. Solvent-based adhesives are non-compliant in many municipalities, though are often used in violation of the VOC (Volatile Organic Compounds) standards set. Because environmental concerns continue to receive ever-increasing priority by local and federal authorities, it is anticipated that the use of solvent-based adhesives and solvent cleaners as described above in this application will be completely banned in several years. Although currently compliant in most areas, water-based solvents and some hot melts may also contain a modest percentage of solvents, and these are also being discontinued in some areas.
It is yet another object of this invention to improve or insure the quality of the finished countertop, etc. Failures of the bonds (delamination) in countertops, etc., have been documented extensively since the introduction of water-borne contact adhesives. While such adhesives eliminate fire risk and mitigate the consequences of non-compliance with emissions regulations, they have been proven to be very unreliable. Virtually every manufacturer, contractor, and installer in the countertop industry is keenly aware of the high potential for product failure when these adhesives are used. Additionally, the quality of bonds made using hot melts and PVA&apo
Ahmad Nasser
Denk Paul M.
LandOfFree
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