GB2032345A

GB2032345A - Continuous press and method for continuously producing consolidated material

Info

Publication number: GB2032345A
Application number: GB7842035A
Authority: GB
Original assignee: Formica Ltd
Current assignee: Formica Ltd
Priority date: 1978-10-26
Filing date: 1978-10-26
Publication date: 1980-05-08
Also published as: ES485287A1; FR2439670A1

Abstract

A continuous press for consolidating one or more webs comprises a pair of rotatable spaced drums 2, 3, means for rotating at least one drum, a continuous flexible belt 1 carried on the drums, means for adjusting the spacing of the drums means 14, 15 for supplying one or more webs, one or more turning bars 16 to divert the web(s) between the belt 1 and drum 3 and a turning bar 21 to divert the pressed product to take up means 20. <IMAGE>

Description

SPECIFICATION Continuous press and method for continuously pro ducing consolidated material This invention relates to a continuous press and a method for continuously producing consolidated material in web form. More especially it relates to a continuous laminating machine and a method for continuously laminating a plurality of webs; still more especially it relates to a continuous laminating machine and a method whereby one, or two laminates simultaneously, may be prepared continuouslyfrom, respectively, one or two assemblies, each of which comprises a plurality of webs.

It is an object of this invention to provide a continuous press which is so fashioned and may be so operated as to consolidate continuously one, or two simultaneously, webs of material so as to provide respectively one, or two simultaneously, consolidated webs. It is also an object of this invention to provide a machine and a method whereby a laminate, or a pair of laminates simultaneously, may be continuously produced from one or a pair of assemblies each comprising a plurality of webs.

It is a further object of this invention to provide a machine and method whereby a thermoset decorative plastics laminate, or a pair of such laminates simultaneously, may be continuously produced from one, or a pair respectively, of assemblies each comprising a plurality of webs at least one of which webs comprises a thermosettable resin impregnated decorative web.

It is a still further object of this invention to provide a continuous press whereby a web of material or a pair of such webs simultaneously, may be consolidated to produce respectively a consolidated web, or a pair of such webs simultaneously, wherein the consolidation is achieved by passage of the, or each, web through a consolidation zone formed between one of a rotating spaced pair of drums and a continuous flexible belt transversing said drums and caused to travel in accordance with the rotation of said drums and wherein the drums and belt are so supported as to facilitate their removal and replacement.

It is a still further object of this invention to provide a continuous press whereby a laminate or a pair of such laminates simultaneously, may be produced by consolidation of one, or a pair respectively, of assemblies each comprising a plurality of webs wherein the consolidation is achieved by passage of the, or each, assembly through a consolidation zone formed between one of a rotating spaced pair of drums and a continuous flexible belt transversing said drums and caused to travel in accordance with the rotation of said drums and wherein the drums and belt are so supported as to facilitate their removal and replacement.

According to one aspect of the invention, a continuous press for continuously consolidating a web or material, or a pair of such webs simultaneously, comprises a pair of spaced drums mounted to rotate on parallel axes, means for rotating one or both said drums in the same direction, so as to cause a continuous flexible belt positioned about both said drums to move in the direction of rotation, said belt being pre-tensioned by suitable adjustment of the spacing between the axes of rotation of the drums, and the belt and drums so co-operating in nip relationship as to consolidate and convey in the direction of rotation any material situated therebetween, one, or a pair of, turning bar ingress means each said ingress means being associated with one, ora different one only, of said drums and comprising a turning member whose axis is inclined to the axes of rotation of the drums, each ingress means being adapted to receive from associated supply means one said web and turn same so as to direct it towards its associated drum and into the inlet side of the nip formed by the belt and said drum, one, or a pair of, turning bar egress means each associated with an ingress means and comprising a turning member whose axis is inclined to the axes of rotation of the pair of drums and each said egress means being adapted to receive consolidated web material emergent from its associated nip and turn and direct same to associated take-up means.

According to another aspect of the invention, a continuous press for continuously forming a laminate or a pair of laminates simultaneously from one, or a pair respectively, of assemblies each comprising a plurality of webs comprises a pair of spaced drums mounted to rotate on parallel axes, means for rotating one, or both said drums in the same direction, so as to cause a continuous flexible belt positioned about both said drums to move in the direction of rotation, said belt being pre-tensioned by suitable adjustment of the spacing between the axes of rotation of the drums, and the belt and the drums so co-operating in nip relationship as to consolidate and convery in the direction of rotation any material situated therebetween, one, or a pair of, turning bar ingress means positioned intermediate said drums each said ingress means being associated with one, or a different one, only of said drums and comprising a turning member whose axis is inclined to the axes of rotation of the drums, each ingress means being adapted to receive from associated supply means one said assembly and turn same so as to direct it towards its associated drum and into the inlet side of the nip formed by the belt and said drum, one, or a pair of, turning bar egress means each associated with an ingress means and comprising a turning member whose axis is inclined to the axes of rotation of the pair of drums and each said egress means being positioned intermediate said drums and adapted to receive consolidated laminated material emergent from its associated nip and turn and direct same to associated take-up means.

According to a further aspect of the invention a continuous press for continuously forming a thermoset plastics laminate or a pair of such laminates simultaneously, each from an assembly comprising a superimposed plurality of fibrous webs at least one web in each assembly being a thermosettable resin composition treated fibrous web, said machine essentially comprising a pair of spaced drums mounted to rotate on parallel axes and at least one of which is adapted to be heated internally, means for rotating one or both of said drums in the same direction so as to cause a continuous flexible belt positioned about both said drums to move in the direction of rotation, said belt being pre-tensioned by suitable adjustment of the spacing between the axes of rotation of the aforesaid drums, the belt and each drum so co-operating in nip relationship as to consolidate and convey in the direction of rotation any material situated therebetween, one or a pair of turning bar ingress means positioned intermediate said drums and each said ingress means being associated with one, or a different one only, of said drums and comprising a turning member whose axis is inclined at an angle to the axes of the drums and each ingress means being adapted to receive from associated feed means one said assembly and turn same so as to deliver it towards its associated drum and into the inlet side of the nip formed by the belt and said associated drum, one, or a pair of, turning bar egress means each associated with an ingress means and comprising a turning member whose axis is inclined at an angle to the axes of the pair of drums and each being positioned intermediate said drums and adapted to receive consolidated laminated material emergent from its associated nip and turn and direct same to associated take-up means.

According to another aspect of the invention, a method for continuously forming laminates singly, or as a pair simultaneously, each from an assembly comprising a superimposed plurality of webs which method comprises receiving each said assembly from feed means and directing same each by associated turning bar ingress means to a nip formed between a continuous flexible belt positioned about and tensioned by a pair of spaced drums, each mounted to rotate on substantially parallel axes, each said ingress means being positioned between the spaced drums and co-operating with one only of said drums and comprising a turning member whose axis is angularly inclined to the axes of the drums, causing said drums to rotate each in the same direction so as to move the belt in the direction of rotation and cause the assembly directed towards the nip (or each said nips) to be consolidated whilst being transported in the direction of the movement of the belt, said consolidation being such as to form a unitary laminate from each said assembly, receiving each said laminate emerging from the nip or each nip, and directing same, each by different turning bar egress means situated between said drums and each co-operating with one only of said drums, each said egress means comprising a turning member whose axis is angularly inclined to the axes of the drum, to associated take-up means.

According to another aspect of the invention a method for continuously forming thermoset plastics laminates singly, or a pair simultaneously, each from an assembly comprising a superimposed plurality of fibrous webs at least one web in each assembly being a thermosettable resin composition treated fibrous web, which method comprises receiving one, or each, said assembly from feed means and directing same, each by associated turning bar ingress means, to a nip formed between a continuous flexible belt positioned about and tensioned by a pair of spaced drums, each said drum to which an assembly is directed being internally heated, each mounted to rotate on substantially parallel axes, each said ingress means being positioned between the spaced drums and co-operating with one only of said drums and comprising a turning member whose axis is angularly inclined to the axes of the drums, causing said drums to rotate each in the same direction so as to move the belt in the direction of rotation and cause the assembly directed towards the nip (or each said nip) to be consolidated and heated by heat transferred from said drum whilst being transported in the direction of the movement of the belt, said consolidation and heating being such as to form a unitary thermoset laminate from each said assembly, receiving each said laminate emerging from the nip or each nip, and directing same, each by different turning bar egress means situated between said drums and each co-operating with one only of said drums each said egress means comprising a turning member whose axis is angularly inclined to the axes of the drums, to associated take-up means.

Machines and methods are known for continuously consolidating materials and wherebythermoset resin laminates may be produced continuously; the most commercially successful of these require expensive and complicated machinery which is difficult to adjust and maintain. These known machines and methods include those wherein a continuous belt traverses a multiplicity of rollers (usually four) and the materials to be laminated are passed between the belt and (usually) one of the rollers, whereby they are heated and pressed to form the desired laminate. Because of the design and construction of these known machines, only one laminate can be produced at a time, despite the fact that the belt traverses at least three rollers.Further because of the design of these conventional machines and the arrangement of the rollers, the continuous belt is usually required to flex in both directions perpendicularto its major surfaces during its passage around one circuit. This double flexion together with the tension applied to the belt limits severely the materials suitable for belt construction and contributes to a relatively short working life for the belt. Still further, because of their construction, it is a complex and time-consuming operation to change or replace a belt when it becomes worn or broken orto replace a roller when such is desired.

In accordance with the objects of the invention, ae continuous press and a method of continuously consolidating material in web form is provided wherein these disadvantages of the known machines are substantially overcome or avoided.

In order that our invention may be more clearly understood, a preferred embodiment adapted to produce a pair of thermoset plastics laminates con tinuously will now be described with reference to the accompanying drawings of which Figure 1 is a partially cut-away perspective view of the machine, Fig ure 2 is an end view of the machine, and Figure3 is an enlarged perspective view of a part of the machine shown in Figure 1.

It should be noted that the Figures generally are schematic and for reasons of clarity various structural components, bearings and other conventional supporting members, have been omitted.

This preferred embodiment is especially useful in the production of a pair of flexible decorative thermoset plastics laminates simultaneously, each from a pair of webs, one of which comprises a thermosettable resin treated decorative paper web and the other a thermosettable resin treated kraft paper web.

The general arrangement of the apparatus will first be described with particular reference to Figure 1.

The apparatus essentially comprises an endless flexible belt 1 comprising a fabric-reinforced elastomeric material which is carried upon a pair of drums 2 and 3 mounted upon horizontal shafts 4 and 5 respectively. The ends of the shaft 4 are journalled in a pair of slidably mounted axle-boxes (one of which is shown by symbol 6) and which are positioned by adjustable stop-screw means, and the shaft 5 is journalled in a pair of slidably mounted axle-boxes (one of which is shown by symbol 7). The axle-boxes 6 and 7 are provided with grooved upper and lower faces which are adapted to slide between respective pairs of horizontal bar frame members 8.

To provide adjustment and tension to the belt a pair of hydraulic cylinders (one of which is shown by symbol 9) and each having an actuating plunger 10 and an associated pump 11, are provided to coact with the axle-boxes 7 thereby to displace and bias the drum 3 in a rightward direction to create a desired belt tension which is proportionally indicated by hydraulic pressure gauges (one of which is shown by symbol P.G.). (It should be noted that for reasons of simplicity only one pair of bar frames and the associated set of hydraulic mechanisms have been included in Figure 1.) The drum 2 is driven in a clockwise direction by means of an electric motor 12 through the medium of a reduction gear box, generally indicated by symbol 13.

The webs are fed into an ingress nip, formed by the interior of the belt 1 and the cylindrical surface of the drum 3, from a pair of web supply reels 14 and 15 via an ingress means comprising a turning bar assembly, which is generally indicated by symbol 16 and which is described in detail below. Supply reel 14 contains a web 17 ofthermosettable-resin-treated decorative paper, and reel 15 contains a web 18 of thermosettable-resi n-treated kraft paper. An assembly of freely running guide rollers 19 is provided to receive the webs from the reels and deliver them in special relationship to the turning bar assembly 16.

Heating means, comprising steam conduits of known type, are provided within the drum 3 to heat the webs during an effective nip angle of 1800 formed between the belt 1 and the drum 3. The consolidated thermoset laminate emerging from the nip is fed to a take-up reel 20 via an egress turning bar means comprising a non-rotating cylindrical bar turning member 21 disposed at an angle of 45" to the belt.

The nip of the drum 2 operates simultaneously with the nip of the drum 3 and serves to consolidate a further pair of webs into a laminate by ingress and egress turning bar means, and 21 A, respectively. The web guiding means and the associated ingress and egress turning bar means (which are indicated by chain-dotted lines), are substantially identical to those described with reference to symbols 16 and 21.

The means for mounting the apparatus will now be described with additional reference to Figure 2 which comprises a simplified end view of the apparatus and includes structural components not shown in Figure 1.

The two pairs of bar frame members 8 are joined together by means of transverse frame plates 22 which pass between the horizontal portions of the belt 1 and are in turn secured to the sides of a pair of pedestal frame supports. Each support comprises a vertical channel-section member 23 which terminates at a fabricated base plate structure 24 at its lower end. The upper extremity of the members support a hood 25 which serves to collect and remove solvents arising from the consolidation of the webs.

The pedestals also support a sub-frame assembly, generally indicated by symbol 26, which provides a mounting means for the web guide rollers 19.

Also in Figure 2 will be seen inlet and outlet flexible steam hoses 27 and 28 for heating the drum 3, and bearing block means, schematically indicated at 29, for mounting the journals of the turning bars.

The ingress means turning bar assembly will now be described in greater detail with reference to Figure 3.

As mentioned above, the webs are guided from the roller system 19 in spatial relationship and a special feature of the apparatus is in the provision of ingress means that maintain this separation until the webs finally reach the ingress nip thereby to prevent scuffing and other damage from taking place.

The upper web 17, comprising the impregnated decorative paper (and which is the lower web after turning), is carried upon the surface of a non-rotating cylindrical turning bar member 30 disposed at an angle of 450 to the belt. The lower web 18, comprising the impregnated kraft paper, is guided within an open-ended guide box structure of helical configuration and disposed concentrically to the bar member 30. The said box comprises two parallel sheet metal panels 31 and 32 which are secured together at their side extremities by strips 33 to define a hollow structure of approximately rectangular cross-section. It should be noted that the structure is positioned so as to provide a circumferential clearance around the bar member 30 thereby to prevent damage to the decorative paper web.

To facilitate entry of the webs prior to starting-up the apparatus, a horizontally disposed flanged guide tray 34 which is attached to the framework by means not shown, is provided temporarily to support the webs and to control transverse register thereof with respect to the belt.

The supply of thermosettable resin impregnated kraft paper is provided on reel 15 and the supply of thermosettable resin impregnated decorative paper provided on reel 14. With the drums 2 and 3 and belt 1 stationary, the free ends of both paper webs are fed via guide rolls 19 to turning bar ingress means 16. The decorative paper is fed externally of guide box 31,32 and 33 to and around turning member 30 and on top of guide tray 34 to the nip formed by belt 1 and roller 3. Similarly the kraft paper is fed to the nip by passage into, through, and out of guide box 31,32 and 33, via its open ends, and above the decorative paper to guide tray 34. The belt 1 is then given a desired tension (suitably determined by prior experiment) by adjustment of the spacing between the drums 2 and 3 by means of the hydraulic cylinders 9, the plungers 10 and the hydraulic pumps 11.

The tension of the belt is determined so that at the speed of rotation of the belt and the temperature of the drum 3, the webs are consolidated to a unitary thermoset laminate during their passage through the nip.

Motor 12 is now started and the drums 2 and 3 and the belt 1 caused to rotate in the direction indicated; the rotation causes the papers to be drawn into and through the nip and pass to turning bar egress means 21. The material leaving the nip and passing to the egress means is caused to traverse the turning member (as indicated in Figure 1), and so, directed and affixed to take-up reel 20 (which comprises a reel driven through a friction clutch so as to maintain a steady tension in the material emerging from the nip). Rotation is then stopped and the drum 3 brought to the required temperature by means of steam traversing steam lines 27 and 28.

With the drum 3 at the required temperature, motor 12 is run so as to cause rotation of drums 2 and 3, and belt 1 and hence draw the webs from their respective supply means via the ingress means at the required rate. (This rate is suitably determined by prior experiment and is such that in conjunction with the tension of the belt, the nature and composition of the webs and the temperature employed, the webs are consolidated to a unitary thermoset laminate during their passage through the nip.

The consolidated thermoset laminate emerging from the nip is then drawn via the egress means to the take-up means by the tension applied to the laminate bythe driven take-up means.

When a pair of laminates simultaneously are to be produced then duplicate supply reels, ingress and egress means and take-up reels are provided in association with drum 2 (the cylindrical turning bar members of the said ingress and egress means only being indicated by 16a and 21a of Figure 1). The start-up and use of the continuous press for production of a pair of laminates simultaneously is as described above except, of course, the operations there described are duplicated in relation to the sec ond feed webs.

In accordance with the invention, webs compris ing, for example, paper, wood veneer, woven and unwoven fabrics, natural or synthetic resins and polymers (whether reinforced or not) may be simply and conveniently consolidated to provide laminates.

The thermosettable resins employed are suitably those known for use in the production of decorative laminates and include for example triazine-aldehyde resins such as melamine-formaldehyde resins, acetoguanamine4ormaldehyde resins and benzoguanamineJormaldehyde resins, ureaformaldehyde resins, polyester resins, acrylic resins and epoxy resins. We prefer to employ triazinealdehyde resins and more especially flexibilised triazine-aldehyde resins.

The continuous flexible belt employed may be prepared from any of the materials known for use in flexible belt production such as for example, flexible steel, natural or synthetic rubbers. We prefer to use a fabric reinforced synthetic elastomer belt having a heat resistance such as to withstand without detriment any heat transferred thereto from the drum(s).

The dimensions of the belt may be any suitable dimensions provided that the length of the belt is such that the drums may be spaced a desired distance apart. Preferably the width of the belt is at least as great as the width of the webs and corresponds substantially to the width of the drums.

The drums may be made of any suitable material; preferably they are formed of a metal such as steel which possesses good heat transfer characteristics and which can be relatively easily provided with a desired surface texture, more especially we prefer to employ drums made of stainless steel or chrome plated steel as such resist corrosion and possess other desirable characteristics.

The drums may be heated internally to the required temperature by any suitable means, such as by electricity, heated oil or steam. We prefer to employ steam as such is readily available and can be easily controiiad to provide the desired temperature.

The surface of the drums may be of any desired finish ortexture. For example, the drums may be embossed or smooth or they may have a highly glossy (mirror) finish, a dull mattfinish or exhibit any intermediate degree of gloss. When preparing decorative laminates according to our invention, we prefer to supply the webs to the nip(s) so that surface of that web which is to provide the decorative effect in the finished laminate is adjacent the surface of the drum. In this manner the laminate produced has a surface texture which closely corresponds with the surface of the drum.

For some combinations of surface texture and thermosettable resins we have found it preferable to provide means to prevent adhesion of the resins to the drum. Such means may comprise, for example, applying a non-stick coating (e.g. polytetrafluorethylene) to the surface of the drum or providing a web of material having non-stick properties (e.g.

polypropylene) between the drum and the thermosettable resin treated webs (this latter may be conveniently done by providing a supply of such material and arranging for itto be fed to and from the nip by similar means to those described for the resin treated webs).

In that preferred embodiment of our invention shown in Figures 1 and 2, the mounting of the drums and their associated equipment on the bar frames carried by the pedestal frames enables the drums and the belt to be quickly and simply replaced. With the arrangement shown, the belt and the drums can be removed from the bar frame by causing the drums to approach each other, so removing the tension from the belt, which can then be slipped off by being drawn away over bar frame 8. The drums can then be removed by drawing them towards and then out of the open ends of the bar frames. It should be understood that our invention is not restricted to the mounting and supporting system illustrated with references to our preferred embodiment and that any suitable system may alternatively be employed.

The supply and take-up means for the webs may likewise be of any convenient form and ourinven- tion is not limited to the reel means 14 and 15 and 20 shown in the drawings relating the preferred embodiment.

Similarly, adjustment of the spacing of the drums may be achieved by any suitable means such as, for example, a mechanical screw adjustment or pneumatic means. We prefer to employ hydraulic means as such are compact and easily and conveniently operated.

In our preferred embodiment we employ guide rollers to direct the lamella from the supply means to the turning bar ingress means. These guide rollers are not an essential feature of the invention and, optionally, may be omitted or replaced by alternative guide means if required.

In our preferred embodiment wherein the turning bar ingress means comprises the non-rotating cylindrical bar turning member in conjunction with a helical guide box, the webs are caused to traverse the means and travel to the nip in superimposed relationship but the construction of said means together with the tension applied to the webs by being drawn around the drum causes them to be maintained spatially separated until they are forced into contact at the entrance to the nip.

The axis of the non-rotating cylindrical bar turning member may be inclined to the axes of the drums at any convenient angle, thus, for example, the axes of the drums and the turning member may all be horizontally disposed but with the axis of the member at 450 to that of the drums (as shown in Figure 1). By this arrangementthe webs are turned through 90 degrees in the horizontal plane in traversing the turning bar ingress means. With the axis of the turning member at angles other than 450 then the webs are turned through angles other than 900.Further the axis of the turning member may, optionally, not lie in the same plane as the axis of the drums so that webs traversing the ingress means are turned in three dimensions, such an arrangement being useful when the material leaving the supply means has its major surfaces vertical and not horizontal as shown in the Drawings.

Optionally, alternative ingress means may be employed if so desired. For example, instead of the preferred single bar and guide box means, a plurality of non-rotating cylindrical turning bar members, corresponding in number to the number of webs being fed to the nip may be employed; this plurality being positioned in side-by-side or stacked arrangement. If such alternative arrangements are employed then, clearly, the supply means must be appropriately disposed.

Further, whilst in the Drawings the supply and take-up means are shown on opposite sides of the machine, it is not essential that they should be so positioned. By suitable disposition of the axis of the turning member in either of the ingress or egress means, both the supply and take-up means may be sited on the same side of the machine.

If desired, a pair of dissimilar laminates may be prepared simultaneously in accordance with the invention. For example, (i) a pair of laminates having the same composition but differing surface textures may be prepared simultaneously by using drums with different surface finishes; (ii) a pair of laminates, one comprised of thermoplastic material and the other comprising thermosettable material, may be prepared simultaneously, optionally, with the drums at different temperatures; (iii) a pair of laminates, one comprising webs adhesively bonded together by the application of pressure and without the use of heat and the other formed from webs comprising a thermosettable resin composition, may be prepared simultaneously by heating the drum which is to be associated with the webs comprising the thermosettable resin composition.

In order that our invention may be more clearly understood the following Examples are given wherein all percentages are by weight.

EXAMPLE 1 A continuous press in accordance with the preferred embodiment of the invention comprised a pair of internally steam heated steel drums 0.5 metre in diameter and 0.25 metre wide and having a chromed satin surface finish and positioned aboutthe drums a continuous reinforced neoprene belt of the same width as the drums.

The drums were spaced apart by hydraulic means so as to apply a tension of 6 metric tonnes to the belt and steam supplied to the drums to provide a surface temperature of about 175 C.

Athermosettable resin impregnated paper web comprising a high quality opaque printed decorative alpha cellulose paper having a basis weight of about 120 g.s.m. and impregnated with a conventional low-pressure melamine-formaldehyde resin to a resin content of about 50% was provided on each of a pair of supply reels.

A thermosettable resin impregnated kraft paper web comprising a kraft paper having a basis weight of about 150 g.s.m. and impregnated, with the same thermosettable low-pressure melamine resin as the decorative sheet, to a resin content of about 35% was provided on each of a second pair of supply reels.

One of each pair of supply reels were situated in stacked relationship in association with the inlet end of one of the nips and were disposed on opposite sides (and in relation to opposite surfaces) of the belt.

The start-up and production of a pair of laminates simultaneously was then carried out as described above with the speed of rotation of the drums at about 2 r.p.m. so that the production rate of the laminates totalled about 7.6 metres/minute. The laminates leaving the nips were collected separately on take-up reels associated with the supply means but situated on the opposite side of the belt.

The thermoset laminates thus formed exhibited a decorative appearance and a satin finish and due to their flexibility they were--after slitting to an appropriate width-adapted for use as edging strip material.

EXAMPLE2 A pair of consolidated thermoset melamineformaldehyde resin impregnated decorative paper webs useful as edging strip materials were simultaneously prepared as follows.

A web of thermosettable melamine-formaldehyde resin impregnated high grade decorative paper of basis weight 250 g.s.m. and having a resin content of about 45% was provided on each of two supply reels.

The reels were positioned one in association with each of the steel drums of a continuous press as related in Example 1 and each web was led by associated supply means (a fixed cylindrical turning bar member) to the inlet side of the nip formed between the belt and the drum associated with the particular web.

The start-up and production of a pair of consolidated thermoset melamine-formaldehyde resin impregnated decorative paper webs was then performed as related in Example 1. The consolidated webs emerging from the nips were each directed by fixed cylindrical bar egress turning means to associated slitting means which severed the webs into strips of the desired width and each strip was then received by and wound upon a take-up spool.

Claims

1. A continuous press for continuously consolidating a web of material, or a pair of such webs simultaneously, comprising a pair of spaced drums mounted to rotate on parallel axes; means for rotating one or both said drums in the same direction; a continuous flexible belt positioned about both said drums adapted to move in the direction of rotation, means for tensioning said belt by adjusting the spacing between the axes of rotation of the drums, the belt and drum so co-operating in nip relationship as to consolidate and convey in the direction of rotation any material situated therebetween, one, or a pair of, turning bar ingress means each ingress means being associated with one, or a different one only, of said drums and comprising a turning member whose axis is inclined to the axes of rotation of the drums, each ingress means being adapted to receive from associated supply means one said web and turn same so as to direct it towards its associated drum and into the inlet side of the nip formed by the belt and said drum, one, or a pair of, turning bar egress means each associated with an ingress means and comprising a turning member whose axis is inclined to the axes of rotation of the pair of drums, said egress means being adapted to receive consolidated web material emergent from its associated nip and turn and direct same to associated take-up means.

2. A continuous press for continuously forming a laminate or a pair of laminates simultaneously from one, or a pair respectively, of assemblies each comprising a plurality of webs, said machine comprising a pair of spaced drums mounted to rotate on parallel axes, means for rotating one, or both said drums in the same direction, a continuous flexible belt positioned about both said drums and adapted to move in the direction of rotation; means for tensioning said belt by adjusting the spacing between the axes of rotation of the drums; said belt and said drums so co-operating in nip relationship as to consolidate and convey in the direction of rotation any material situated therebetween; one, or a pair of, turning bar ingress means positioned intermediate said drums, each ingress means being associated with one, or a different one, only of said drums and comprising a turning member whose axis is inclined to the axes of rotation of the drums and being adapted to receive from associated supply means one said assembly and turn same so as to direct it towards its associated drum and into the inlet side of the nip formed by the belt and said drum, one, or a pair of, turning bar egress means each associated with an ingress means and comprising a turning member whose axis is inclined to the axes of rotation of the pair of drums and each egress means being positioned intermediate said drums and adapted to receive consolidated laminated material emergent from its associated nip and turn and direct same to associated take-up means.

3. A continuous press for continuously forming a thermoset plastics laminate, or a pair of such laminates simultaneously, each from an assembly comprising a superimposed plurality of fibrous webs at least one web in each assembly being a thermosettable resin composition treated fibrous web, said machine comprising a pair of spaced drums mounted to rotate on parallel axes, at least one of which is adapted to be heated internally, means for rotating one or both of said drums in the same direction, a continuous flexible belt positioned about both said drums and adapted to move in the direction of rotation; means fortensioning said belt by adjusting the spacing between the axes of rotation of the aforesaid drums, said belt and said drums so cooperating in nip relationship as to consolidate and convey in the direction of rotation any material situated therebetween; one or a pair of turning bar ingress means positioned intermediate said drums, each ingress means being associated with one, or a different one only, of said drums and comprising a turning member whose axis is inclined at an angle to the axes of the drums and being adapted to receive from associated feed means one said assembly and turn same so as to deliver it towards its associated drum and into the inlet side of the nip formed by the belt a d said associated drum, one, or a pair of, turning bar egress means each associated with an ingress means and comprising a turning member whose axis is inclined at an angle to the axes of the pair of drums and being positioned intermediate said drums and adapted to receive consolidated laminated material emergent from its associated nip and turn and direct same to associated take-up means.

4. A continuous press as claimed in any preceding claim wherein the surface finish of the drums is the same or different.

5. A continuous press as claimed in any preceding claim wherein each of the drums is provided with a shaft about which the drum rotates, each said shaft being journalled at each end in an axle box having grooved upper and lower faces and the axle boxes on corresponding ends of the shafts being slideably mounted between respective pairs of horizontal bar members, the members of each pair being in parallel array, one vertically above the other and the pairs being horizontally disposed in parallel relationship to each other.

6. A method for continuously forming laminates singly, or as a pair simultaneously, each from an assembly comprising a superimposed plurality of webs which method comprises receiving each said assembly from feed means and directing same each by associated turning bar ingress means to a nip formed between a continuous flexible belt positioned about and tensioned by a pair of spaced drums, each mounted to rotate on substantially parallel axes, each said ingress means being positioned between the spaced drums and cooperating with one only of said drums and comprising a turning member whose axis is angularly inclined to the axes of the drums, causing said drums to rotate each in the same direction so as to move the belt in the direction of rotation and cause the assembly directed towards the nip (or each said nips) to be consolidated whilst being transported in the direction of the movement of the belt, said consolidation being such as to form a unitary laminate from each said assembly, receiving each said laminate emerging from the nip or each nip, and directing same, each by different turning bar egress means situated between said drums and each cooperating with one only of said drums each said egress means comprising a turning member whose axis is angularly inclined to the axes of th drum, to associated take-up means.

7. A method for continuously forming thermoset plastics laminates singly or a pair simultaneously, each from an assembly comprising a superimposed plurality of fibrous webs at least one web in each assembly being a thermosettable resin composition treated fibrous web, which method comprises receiving one, or each, said assembly from feed means and directing same, each by associated turning bar ingress means, to a nip formed between a continuous flexible belt positioned about and tensioned by a pair of spaced drums, each said drum to which an assembly is directed being internally heated, each mounted to rotate on substantially parallel axes, each said ingress means being positioned between the spaced drums and cooperating with one only of said drums and comprising a turning member whose axis is angularly inclined to the axes of the drums, causing said drums to rotate each in the same direction so as to move the belt in the direction of rotation and cause the assembly directed towards the nip (or each said nip) to be consolidated and heated by heat transferred from said drum whilst being transported in the direction of the movement of the belt, said consolidation and heating being such as to form a unitary thermoset laminate from each said assembly, receiv ing each said laminate emerging from the nip or each nip, and directing same, each by differentturn- ing bar egress means situated between said drums and each co-operating with one only of said drums each said egress means comprising a turning member whose axis is angularly inclined to the axes of the drums, to associated take-up means.

8. A method as claimed in Claim 7 wherein the, or each, assembly comprises a thermosettable resing impregnated decorative paper web and a thermosettable resin impregnated kraft paper web.

9. A method as claimed in Claim 8 wherein the decorative paper web and the kraft paper web are impregnated with the same or different thermosettable resins selected from the group comprising triazine-aldehyde resins, urea-formaldehyde resins, polyester resins, acrylic resins and epoxy resins.

10. A method as claimed in Claim 9 wherein the triazine-aldehyde resin is a flexibilised triazinealdehyde resin.