Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – Deforming the surface only
Patent
1996-06-27
1999-03-16
Kuhns, Allan R.
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
Deforming the surface only
264321, 425 73, 425385, 425397, 425398, B29C 5902
Patent
active
058825690
DESCRIPTION:
BRIEF SUMMARY
This invention concerns a method for manufacturing decorative panels with a decoration in relief on at least one of the broad sides of the panel.
According to a known method, such decorative panels are at present made by attaching the decorations to the panel by means of adhesive, screws or suchlike. A disadvantage of this method is that these decorations become detached or cracked in the course of time. Furthermore, it is generally necessary to apply an additional coat of paint over the assembly.
Another known method consists of sticking a PVC sheet 2 to 3 mm thick, formed under vacuum, onto a core of wood or plastic. In this case it is observed that after a certain time this film becomes detached or cracked due to differences in the coefficient of expansion.
Furthermore, the method at present used for making such decorative panels is very tedious and labour-intensive. In connection with said known methods the following patent specifications among others should be referred to: EP 0288.728, EP 0206.755, EP 299.168, U.S. Pat. No. 4,643,787.
The aim of the present invention is to overcome these different disadvantages, and to offer a method which completely precludes the detachment or cracking of the decorations and furthermore is much simpler than the existing methods.
According to the invention, one begins with a hard, at least partly thermoplastic artificial resin foam sheet which is substantially evenly heated on one of its broad sides until a soft, plastic mass is obtained in which all residual stresses are released, to which the decoration in the form of a raised and/or sunken relief is then applied on said softened side by means of a mould, such as a die or stamp.
The sheet can advantageously be heated substantially evenly through its full thickness, preferably by means of hot air circulation.
In a particular embodiment of the invention, the mould is kept at a temperature between the approximate maximum temperature at which the sheet is still hard and the temperature at which the decoration is pressed in the soft sheet.
In a preferred embodiment, the die or stamp is kept in the pressing position after pressing and is cooled along with the sheet until the latter is substantially hard once more.
The invention also concerns an installation for applying the method described above.
Said installation is characterised by the fact that it comprises an oven part and a pressing part, said oven part comprising a thermally insulated chamber which can be closed, in which at least one sheet to be heated can rest substantially horizontally on a support, at a certain distance from the bottom of said chamber, with means being provided to create a stream of hot air around said sheet.
Other characteristics and advantages of the invention may be seen from the following description of a specific embodiment of the method and installation for making decorative panels according to the invention; this description is given for the sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view with a partial cross section of a decorative panel according to a first embodiment of the invention.
FIG. 2 is a perspective view with a longitudinal section of a decorative panel according to a second embodiment of the invention.
FIG. 3 is a schematic cross section of a detail of a mould and a hard foam sheet with sunken relief.
FIG. 4 is a schematic cross section of a mould and a hard foam sheet with raised relief.
FIG. 5 is a schematic vertical cross section of an oven part of a particular embodiment of an installation according to the invention, for heating a hard foam sheet.
FIG. 6 is a section along line VI--VI in FIG. 5.
FIG. 7 is a section along line VII--VII in FIG. 5.
FIG. 8 is a schematic representation of a section VIII--VIII of FIG. 6 with a sagging, soft foam sheet.
FIG. 9 is a perspective view with a partial cross section of the pressing section of the installation according to the same em
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