Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Patent
1981-06-19
1983-03-15
Hoag, Willard E.
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
156216, 156223, 264512, 264261, 264320, 425812, B29C 1702, B29G 300
Patent
active
043767486
DESCRIPTION:
BRIEF SUMMARY
The invention relates to a method of forming a slab having at least one profiled edge, said slab comprising a base sheet and a cover sheet connected herewith, the cover sheet being partly connected with the base plate in a manner such that a peripheral part of the cover sheet protrudes beyond the edge of the base sheet in the proximity of which the profiled edge has to be formed.
Such a method is known from U.S. Pat. No. 3,392,074. Herein a filling piece having the profile of the profiled edge is arranged at the edge of the base sheet, after which the cover sheet is glued to the filling piece under pressure. A disadvantage of this method is that due to the curved face of the profiled edge it is particularly difficult to ensure that during gluing the pressure should be everywhere sufficiently high. If the pressure is not sufficiently high, the glue connection becomes locally defective and hence the cover sheet will not satisfactorily join the filling piece. Where the junction is not satisfactory, the cover sheet may readily crack when struck. Moreover, the insufficiently joined parts may form bubbles in the course of time and under the influence of heat. A further disadvantage resides in that the insert is expensive because it has to be of hard wood in order to ensure adequate resistance to strokes on the profiled edge, and it has to be milled into the desired profile.
The invention has for its object to manufacture such a slab in a simpler manner so that the occurrence of non-joining parts of the cover sheet is avoided. According to the invention this is achieved by a method comprising the following successive steps:
a. positioning of the base sheet with the cover sheet partly connected herewith with respect to a mold having the profile of the profiled edge and nestling an outer face of the peripheral part of the cover sheet against said mold,
b. filling out the space bounded by the peripheral part of the cover sheet and the edge of the base sheet with curable filling agent adhering to the two sheets,
c. allowing the filling agent to cure and
d. removing the slab out of the mold.
Because the filling agent is introduced into the space in the liquid state, it comes into contact with the entire surface of the cover plate bounding said space so that subsequent to curing of the filling agent there are no non-joining parts. Since the cumbersome arrangement of the filling piece on the base sheet is avoided, the method according to the invention is materially simpler. For this reason and because no expensive, profiled hard-wood insert is required, the ready slab is appreciably cheaper.
By causing the edge of the base sheet to project into the profiled edge, filling agent can advantageously be saved. This effect is further enhanced by roughly profiling the edge according to the profile of the profiled edge so that the space between the edge of the base sheet and the peripheral part of the cover sheet is small.
When the step defined in claim 4 is used, the head edge of the connecting face between the base sheet and the cover sheet becomes a straight line so that, when the profiled edge has a bend directly from said head edge, it will also extend along a straight line.
The method is advantageously employed for manufacturing a kitchen dresser slab or the like, in which the base sheet is a plywood or wood fibre sheet and the cover sheet is a thermo-hardening synthetic resin sheet of a post-formable type. The curing process therein is not yet completed and by heating the cover sheet it can still once be plastically deformed.
The method according to the invention is particularly suitable for manufacturing a kitchen dresser slab with a water-arresting rim.
To attain a swift fabrication and a good filling of the space, the curable filling agent is preferably pressure fed into the space between the cover sheet and the base sheet.
The invention relates furthermore to and provides a device for molding a slab having at least one profiled edge, said device comprising a connecting device connecting a cover sheet partly with a ba
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