IES970232A2 - A manufacturing process - Google Patents

Abstract

A chipboard core panel (2) is shaped (20) and after cleaning (27) adhesive is coated on top and bottom faces of the panel (2). At a sheeting station (32), a moisture resistant backing sheet is applied to the rear face of the panel (2). Then the panel (2) is laid up on a decorative formica facing sheet (44). The laminated panel (2) is delivered to a press (47). Downstream of the press (47), the panel (2) is trimmed (49) and has adhesive sprayed (51) onto a curved front side face of the panel (2). After heating (55) the panel, an outwardly extending lip of the formica facing sheet (44) is progressively folded (60) upwardly in a controlled manner to cover the curved front side face of the panel (2). A shallow groove is cut (68) in a bottom front edge of the panel (2) and at a waxing station (69) a liquid wax is delivered into the groove end inwardly of the groove to form a wax sealing strip. Downstream of the waxing station (69), the wax is cooled (72) and an edging strip is applied to a rear side face of the panel (2). <Fig. 1>.

Description

This invention relates to a manufacturing process for producing a laminated worktop, and in particular for producing formica faced worktops.

According to the invention, there is provided a 5 manufacturing process for producing a laminated worktop, including the steps: delivering a reconstituted wood core panel through a shaping machine, shaping opposite side faces of the panel to pre-set desired profiles comprising a flat rear side face substantially perpendicular to top and bottom faces of the panel, and a curved front side face, cleaning the panel, delivering the panel between a pair of spacedapart gluing rollers, applying a coating of adhesive from the gluing rollers onto the top face and the bottom face of the panel as the panel passes between the gluing rollers, leading a moisture resistant paper backing sheet from a supply reel around a guide roller, delivering the adhesive coated panel past the guide roller, engaging a free leading edge of the backing sheet with a front end of the bottom face of the panel, OPEN TO PDPUC SMSPfiCTION AW RULE 23 <>iL- SO....../£/5......CF IE 970232 - 2 pulling the backing sheet from the supply reel by feeding the panel past the guide roller, evenly rolling the backing sheet onto the bottom face of the panel covering the bottom face of the panel with the backing sheet, transversely cutting the backing sheet intermediate the guide roller and a rear end of the panel when the panel has passed the guide roller, laying the panel onto a thin decorative facing sheet, the adhesive coated top face of the panel engaging with an inner face of the decorative facing sheet, a front side of the facing sheet projecting outwardly of the curved front side face of the panel forming an outwardly projecting side lip, delivering the panel to a press, applying a preset pressure to opposite faces of the panel and applying heat to the panel for a pre-set time period, discharging the panel from the press, spraying an adhesive onto the curved front side face of the panel and onto an inside face of the outwardly projecting side lip of the decorative facing sheet adjacent the curved front side face of the panel, passing the panel through a heater, IE 970232 - 3 progressively folding the side lip of the facing sheet around the curved front side face of the panel in a controlled manner, delivering the panel past rollers for smoothing 5 · and pressing the lip into engagement with the curved front side face of the panel, cutting a shallow groove in the bottom face of the panel along the curved front side face, filling the groove with a liquid wax and applying a wax coating along the bottom face of the panel inwardly of the groove a pre-set distance, leading a moisture resistant sealing strip from a supply reel, and coating the flat rear side face of the panel with adhesive, pressing the strip along the rear side face to complete the worktop panel.

In a preferred embodiment, the process includes the step of keeping the backing sheet taut as it is drawn from the supply reel by applying a bias to the supply reel resisting delivery of the backing sheet from the supply reel.

In another embodiment, the process includes the step of pressing the backing sheet between the guide roller and the bottom face of the panel as the panel is delivered past the guide roller.

In a further embodiment, the process includes the step of frictionally engaging an outer face of the backing sheet IE 970232 - 4 by means of a plurality of spaced-apart gripper rings mounted in circumferential grooves in the guide roller.

In another embodiment, the process includes folding the lip of the decorative facing sheet around the curved edge of the panel by delivering the panel past an inclined folding arm, engaging a lower leading end of the arm with an inner portion of the lip, the contact point between the arm and the lip moving progressively outwardly as the panel is being delivered past the arm for progressively curving the lip around the curved edge of the panel.

In a preferred embodiment, the process includes the step of cooling the wax seal by directing a stream of cooling air at the wax seal.

In another embodiment, the process includes delivering a prepared decorative sheet onto a press feed conveyor, feeding the panel above the decorative facing sheet, aligning the panel with the backing sheet attached above the decorative facing sheet, engaging a front end of the panel with a front end of the decorative facing sheet, holding the front end of the panel in engagement with the front end of the decorative sheet, pivoting the panel downwardly about the front end of the panel into engagement with the decorative facing sheet.

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:Fig. 1. is a schematic flow chart illustrating a manufacturing process according to the invention; IE 970232 - 5 Fig. 2 is a schematic side elevational view showing portion of a production line for carrying out the process; Fig. 3 is a detail side elevational view showing 5 laminating apparatus of the production line for carrying out the process; Fig. 4 is a view similar to Fig. 3 showing the apparatus in another position of use; Fig. 5 is a view similar to Fig. 3 showing the apparatus in a further position of use; Fig. 6 is a detail side elevational view of portion of the apparatus shown in Fig. 3; Fig. 7 is a detail perspective view of portion of a laminated panel formed in the apparatus of Fig. 3; Fig. 8 is a plan view showing another portion of the apparatus for carrying out the process; Fig. 9 is a detail sectional elevational view showing the application of adhesive to a side face of the panel; Fig. 10 is a detail perspective view of an edge folding station forming portion of the apparatus for carrying out the process; Fig. 11 is a detail sectional elevational view of 25 portion of the folding station; IE 970232 - 6 Fig. 12 is a detail sectional elevational view of another portion of the folding station; Fig. 13 is a plan view of edging apparatus used in the process; Fig. 14 is a detail elevational view of the apparatus shown in Fig. 13; Fig. 15 is a detail, perspective cut-away view of portion of a laminated worktop formed according to the process; and Fig. 16 is a detail sectional elevational view of portion of the worktop.

Referring to the drawings, a process and apparatus for forming a laminated worktop according to the invention will be described.

Referring initially to Fig. 15 a worktop formed according to the process of the invention is shown and is indicated generally by the reference numeral 1. The worktop 1 comprises a core panel 2 of chipboard or other reconstituted wood having a top face 3, a bottom face 4, a curved front side face 5 and a straight rear side face 6. A decorative formica facing sheet 7 is adhesively bonded to the top face 3 and front side face 5. A moisture resistant paper backing sheet 8 is bonded to the bottom face 4 of the panel 2. Secured along the rear side face 6 is a moisture resistant paper back edge sealing strip 9. Extending along a front lower edge of the worktop 1 is a moisture resistant wax front edge seal 10. The wax seal 10 comprises an enlarged head portion 11 which engages within an associated groove 12 extending along the front lower edge of the panel 2 and a tail IE 970232 - Ί portion 14 extending rearwardly from the head portion 11 a pre-set distance, typically about 25mm, inwardly of the front side face 5.

Referring to Fig. 2, rectangular chipboard core panels 2 are delivered to a shaping machine 20. The chipboard panels 2 are arranged in a stack 21 carried on a platform 22 which is vertically movable by a ram operated scissors linkage 23 on a base frame 24 to align an uppermost panel 2 with an inlet opening of the shaping machine 20. A feeding arm (not shown) is engagable with a rear end of the uppermost panel 2 to urge the panel 2 forwardly into the inlet opening of the shaping machine 20. Within the shaping machine 20 the panel 2 is machined to the desired width, and the flat rear side face 6 which is substantially perpendicular to the top face 3 and bottom face 4 and the curved front side face 5 are formed.

Downstream of the shaping machine 20 each panel 2 passes through a cleaner 27 within which loose particles and dust are removed by vacuum. The panel 2 then travels through a gluing station 29. At the gluing station 29 each panel 2 is delivered between a pair of spaced-apart gluing rollers 30. A coating of adhesive is applied onto the top face 3 and bottom face 4 of the panel 2 as it passes between the gluing rollers 30.

Downstream of the gluing station 29 the panel 2 is delivered to a sheeting station 32 (Fig. 3) at which the backing sheet 8 is applied to the panel 2. It will be noted that the panel 2 is carried on a conveyor 33 which comprises rows of spaced-apart upright disks 34. The side edges of the disks 34 support and convey the panel 2 minimising contact with the adhesive coated surface of the panel 2.

IE 970232 - 8 At the sheeting station 32 a moisture resistant paper backing web 35 is led from a supply roll 36 which is carried on a rotatable spindle 37 around a guide roller 38 for application to the uppermost surface of the panel 2 which is the bottom face 4. A free front edge 40 of the web 35 is adhered to a leading edge of the panel 2. A movable feed conveyor 42 travelling in direction X (Fig. 3) engages an underside of the panel 2 and draws the panel 2 along beneath the guide roller 38 which evenly rolls the backing web 35 onto the bottom face 4 of the panel 2 covering the bottom face 4 of the panel 2 with the backing web 35. When the panel 2 has been delivered fully past the guide roller 38 a cutter blade is delivered transversely across the backing web 35 to sever the backing sheet 8 which is adhered to the bottom face 4 of the panel 2 from the backing web 35.

Prior to applying the backing sheet 8 to the panel 2, a decorative formica facing sheet 44 is positioned and aligned on a press feed conveyor 46 beneath the travel path of the movable feed conveyor 42.

The movable feed conveyor 42 is retracted from beneath the panel 2 dropping the panel 2 onto the decorative formica facing sheet 44, the panel 2 engaging with an inner face 45 of the formica facing sheet 44. It will be noted that the panel 2 is carried by the feed conveyor 42 above the formica sheet 44 and aligned with the formica sheet 44. As shown in Fig. 5 a front end of the panel 2 is engaged with a front end of the formica sheet 44 and held in engagement with the formica sheet 44. Then as the feed conveyor 42 is retracted the panel 2 is pivoted downwardly about the front end of the panel 2 into engagement with the formica sheet 44. A stop arm 48 (Fig. 6) pivots downwardly to engage a rear edge of the panel 2 to prevent the panel 2 moving rearwardly as the conveyor 42 retracts. - 9 IE 970232 A cross transfer conveyor (not shown) engages and moves the laminated panel 2 sideways and then a second decorative formica facing sheet 44 is positioned on the conveyor 46 for reception of another panel 2 in the manner previously described.

Then both panels 2 are delivered by the press feed conveyor 46 side by side into a press 47. Within the press 47 a pre-set pressure is applied to opposite faces of the panels 2 and heat is applied to the panels 2.

Downstream of the press 47 the panels 2 are delivered by conveyor 48 to a post forming machine 49 which cuts away excess paper from the backing sheet 8 and excess portions of the formica sheet 44. Each panel 2 is delivered by a conveyor 50 past an adhesive spray 51 in which a number of spray jets of adhesive are directed at the curved front side face 5 of the panel 2 and at an inside face of an outwardly projecting lip 53 of the formica sheet 44.

Downstream of the adhesive spray 51 the panels 2 pass through a heater 55 which initiates curing of the adhesive and also softens the lip 53 of the formica sheet 44 to facilitate bending of the lip 53 around the curved front side face 5 of the panel 2.

Referring to Fig. 10 a folding station 60 is shown. At the folding station 60 the lip 53 is progressively folded around the curved edge 5 of the panel 2 in a controlled manner. The panel 2 is delivered past an inclined folding arm 62. A lower leading end 63 of the arm 62 engages with an inner portion of the lip 53. As the panel 2 moves past the arm 62 the contact point between the arm 62 and the lip 53 moves progressively outwardly for smoothly and gently curving the lip 53 around the curved front side IE 970232 - 10 face 5 of the panel 2. An edging roller 66 also engages the lip 53 to ensure a smooth lay down of the lip 53 around the curved edge. Downstream of the arm 62 a plurality of edging rollers 67 engage against the folded lip 53 for smoothing and holding the lip 53 in engagement with the curved front side face 5.

In a cutting machine 68 a shallow groove 12 is cut in the bottom face 4 of the panel 2 along the curved front side face 5. At a waxing station 69, liquid wax is delivered into the groove 12 and coated along the bottom face 4 of the panel 2 inwardly of the groove 12 a pre-set distance, typically about 25mm.

A sealing strip 9 is drawn from a supply reel 70. A flat rear side face 6 of the panel 2 is coated with adhesive and then the strip 9 is applied along the rear side face 6 to seal the rear edge 6. At the same time cooling air is delivered in jets from an air distributor 72 which directs a cooling air stream at the wax seal 10 to set the wax. The worktop thus produced can then be delivered onto pallets for shipping or may be enclosed in a shrink wrap package prior to packing on pallets.

It will be appreciated that the invention provides a manufacturing process for the production of laminated worktops. The moisture-resistant backing sheet is laid up on the panel in a simple and trouble-free fashion. Conveniently, the weight of the spindle on which the backing sheet supply reel is mounted is chosen so as to provide a resistance which keeps the backing sheet taut as it is laid onto the bottom face of the panel. The apparatus used is of relatively simple construction and is thus reliable in operation whilst at the same time accurately coating the bottom face of the panel with the backing sheet.

IE 970232 - 11 It will also be appreciated that the controlled folding of the lip of the formica sheet around the curved side face of the panel facilitates a good bonding of the formica sheet to the panel with an accurate and smooth surface finish on the formica sheet without bulging or wrinkling.

Further, use of a wax sealing strip on a bottom front edge of the panel provides an effective water barrier relatively cheaply and also conveniently the wax is safe to handle and easily applied to the panel.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (5)

1. A manufacturing process for producing a laminated worktop, including the steps: delivering a reconstituted wood core panel through a shaping machine, shaping opposite side faces of the panel to pre-set desired profiles comprising a flat rear side face substantially perpendicular to top and bottom faces of the panel, and a curved front side face, cleaning the panel, delivering the panel between a pair of spacedapart gluing rollers, applying a coating of adhesive from the gluing rollers onto the top face and the bottom face of the panel as the panel passes between the gluing rollers, leading a moisture resistant paper backing sheet from a supply reel around a guide roller, delivering the adhesive coated panel past the guide roller, engaging a free leading edge of the backing sheet with a front end of the bottom face of the panel, pulling the backing sheet from the supply reel by feeding the panel past the guide roller, evenly rolling the backing sheet onto the bottom face of the panel covering the bottom face of the panel with the backing sheet, IE 970232 - 13 transversely cutting the backing sheet intermediate the guide roller and a rear end of the panel when the panel has passed the guide roller, laying the panel onto a thin decorative facing sheet, the adhesive coated top face of the panel engaging with an inner face of the decorative facing sheet, a front side of the facing sheet projecting outwardly of the curved front side face of the panel forming an outwardly projecting side lip, delivering the panel to a press, applying a preset pressure to opposite faces of the panel and applying heat to the panel for a pre-set time period, discharging the panel from the press, spraying an adhesive onto the curved front side face of the panel and onto an inside face of the outwardly projecting side lip of the decorative facing sheet adjacent the curved front side face of the panel, passing the panel through a heater, progressively folding the side lip of the facing sheet around the curved front side face of the panel in a controlled manner, delivering the panel past rollers for smoothing and pressing the lip into engagement with the curved front side face of the panel, IE 970232 - 14 cutting a shallow groove in the bottom face of the panel along the curved front side face, filling the groove with a liquid wax and applying a wax coating along the bottom face of the panel inwardly of the groove a pre-set distance, leading a moisture resistant sealing strip from a supply reel, and coating the flat rear side face of the panel with adhesive, pressing the strip along the rear side face to complete the worktop panel.

2. A process as claimed in claim 1 wherein the process includes the step of keeping the backing sheet taut as it is drawn from the supply reel by applying a bias to the supply reel resisting delivery of the backing sheet from the supply reel, and preferably the process includes the step of pressing the backing sheet between the guide roller and the bottom face of the panel as the panel is delivered past the guide roller, and preferably the process includes folding the lip of the decorative facing sheet around the curved edge of the panel by delivering the panel past an inclined folding arm, engaging a lower leading end of the arm with an inner portion of the lip, the contact point between the arm and the lip moving progressively outwardly as the panel is being delivered past the arm for progressively curving the lip around the curved edge of the panel, and preferably the process includes the step of cooling the wax seal by directing a stream of cooling air at the wax seal. IE 970232 - 15

3. A process as claimed in any preceding claim wherein the process includes delivering a prepared decorative sheet onto a press feed conveyor, feeding the panel above the decorative facing sheet, aligning the panel 5 with the backing sheet attached above the decorative facing sheet, engaging a front end of the panel with a front end of the decorative facing sheet, holding the front end of the panel in engagement with the front end of the decorative sheet, pivoting the panel 10 downwardly about the front end of the panel into engagement with the decorative facing sheet.

4. A process for producing a laminated worktop substantially as hereinbefore described with reference to the accompanying drawings. 15

5. A laminated worktop whenever produced by the process as claimed in any preceding claim.