Adhesive bonding and miscellaneous chemical manufacture – Methods
Reexamination Certificate
1998-08-07
2001-08-14
Gallagher, John J. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
C118S227000, C118S503000, C156S563000
Reexamination Certificate
active
06273976
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for fabricating a laminated panel. More particularly, the invention relates to a method and apparatus for transporting panel substrates with adhesive on both sides such that the panel substrates may be used in the manufacture of multi-layer decorative panels.
2. Description of the Prior Art
Furniture, desks, partitions, flooring decorative surface and other decorative structures are often constructed from decorative panels. These panels are commonly composed of a central substrate with decorative laminates bonded to opposite sides of a central panel substrate. For example, a wood grain panel is constructed by applying wood grain laminates to opposite sides of a particle board substrate.
When the decorative laminates bonded to the substrate are relatively thick, the manner in which adhesive is applied to the substrate is of little consequence. Specifically, the thickness of the decorative laminates hides any irregularities in the adhesive bonding the substrate and decorative laminate.
However, as the thickness of the decorative laminates decreases it becomes very important to ensure that the adhesive layer contains no undesirable irregularities. Because of the thinness of such decorative laminates, any irregularities may show through or effect the decorative laminate in an undesirable manner. While the term decorative laminates is used above to discuss the prior art, it should be understood by those of ordinary skill in the art that the decorative surfacing layer, for example, the decorative laminate, may take various forms.
The present invention allows for the handling of a substrate which has been treated with adhesive on both sides without disturbing the adhesive coating. In this way, the present invention overcomes the shortcomings of prior art devices employing conveyor rollers or chains that necessarily contact one side of the adhesive coated substrate in order to transport it.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an apparatus for transporting panel substrates with adhesive on both sides such that the panel substrates may be used in the manufacture of decorative panels. The apparatus includes an adhesive applicator which coats a panel substrate with adhesive. The apparatus also includes a first edge support member and a second edge support member located adjacent an outlet end of the adhesive applicator such that edges of the panel substrate are respectively supported by the first edge support member and the second edge support member without interfering with the adhesive being applied to the panel substrate. The apparatus further includes a support for selectively supporting the coated panel substrate and releasing the panel substrate so as not to substantially interfere with the adhesive applied to the panel substrate by the adhesive applicator.
It is also an object of the present invention to provide an apparatus wherein the adhesive applicator coats opposite sides of the panel substrate.
It is a further object of the present invention to provide an apparatus wherein the first edge support member and the second edge support member are selectively mounted to accommodate panel substrates of different widths.
It is another object of the present invention to provide an apparatus wherein the first edge support member and the second edge support member are angled so as to contact only the edges of the panel substrate.
It is also an object of the present invention to provide an apparatus wherein the first edge support member and the second edge support member include rollers which contact the edges of the panel substrate.
It is a further object of the present invention to provide an apparatus including additional pairs of edge support members.
It is also an object of the present invention to provide an apparatus wherein the support includes a static support having a recess for accommodating a surfacing material adapted to be bonded to the panel substrate.
It is another object of the present invention to provide an apparatus wherein the support includes a static support and a release support lip, and the static support and the release support lip selectively support the panel substrate.
It is also an object of the present invention to provide an apparatus wherein the release support lip selectively rotates to release the panel substrate.
It is a further object of the present invention to provide an apparatus wherein the support includes a static support and a roller trolley assembly, and the static support and the roller trolley assembly selectively support the panel substrate.
It is another object of the present invention to provide an apparatus wherein the roller trolley assembly selectively moves to release the panel substrate.
It is a further object of the present invention to provide an apparatus wherein the roller trolley assembly includes a first set of rollers and a second set of rollers oriented to engage opposite edges of the panel substrate.
It is another object of the present invention to provide an apparatus wherein the first set of rollers and the second set of roller are angled so as to contact only the edges of the panel substrate.
It is also an object of the present invention to provide a method for manufacturing a panel. The method includes applying adhesive to at least one side of a panel substrate, supporting the panel substrate with edge support members such that the edge support members do not interfere with the adhesive applied to the at least one side of the panel substrate, moving the panel substrate to a selective support system, suspending the panel substrate over a piece of surfacing material, and releasing the panel substrate down onto the surfacing material such that adhesive on the panel substrate contacts the surfacing material.
It is a further object of the present invention to provide a method including the step of applying a top surfacing material to an opposite side of the panel substrate.
It is another object of the present invention to provide a method including the step of bonding the formed panel.
It is also an object of the present invention to provide a method wherein the step of applying includes applying adhesive to opposite sides of the panel substrate.
It is a further object of the present invention to provide a method including the step of applying a top surfacing material to an opposite side of the panel substrate.
It is another object of the present invention to provide a method wherein the step of releasing includes releasing a first end of the panel substrate onto the surfacing material.
It is also an object of the present invention to provide a method wherein the surfacing material is supported by a conveyor.
Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.
REFERENCES:
patent: 3492182 (1970-01-01), Howard
patent: 3895984 (1975-07-01), Cone et al.
patent: 4177101 (1979-12-01), Evans
patent: 4288274 (1981-09-01), Holz
patent: 4986873 (1991-01-01), Hamamura
patent: 970232 (1997-07-01), None
Hoelscher Wayne A.
McSpedon John P.
Oliver Jay T.
Schumann William R.
Gallagher John J.
Premark RWP Holdings, INC.
Welsh & Flaxman LLC
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