APPARATUS FOR COVERING A SURFACE AND THE EDGES OF A PANEL OF WOODEN OR LIKE MATERIAL WITH A SHEET OF THERMODEFORMABLE MATERIAL

Abstract: An apparatus for covering a surface and the edges of panels of wooden material with a sheet of thermodeformable plastic material, of the type for application to a press with a lower heated bed of elastically yieldable material and a rigid upper platen, the distance of which from the lower bed is variable between a maximum value which enables said sheet of thermodeformable material, the panels to be covered, the retainers and the spacers to be interposed, and a minimum value at which the pressing stage is effected, characterised by comprising: a frame (10) of spacers (11) removably attachable to the upper platen (2) of the press (1); a plurality of spacers (11) applied to said frame (10), each spacer (11) being provided with at least one hole (12) connecting its lower surface to a suction circuit (13) connected said frame (10), and seal means (14) surrounding said hole; a conveyor (19) for conveying thermodeformable plastic laminate sheets (8) from a position outside said press (1) to a position within it, said conveyor being provided with means (25) for picking up and discharging said sheets (8); a jig (27) for positioning a plurality of panels (7) to be covered, and provided with said spacers (11) on said frame (10); and means (19) for transferring said positioning jig (27) from the outside to the inside of the press (1) and for raising it when inside the press, in order to bring the panels (7), located in their respective seats, into contact with the corresponding spacers (11).

Description: APPARATUS FOR COVERING A SURFACE AND THE EDGES OF A PANEL OF WOODEN OR LIKE MATERIAL WITH A SHEET OF THERMODEFORMABLE MATERIAL This invention relates to an apparatus far covering a surface and the edges of a panel of wooden or like material with a sheet of thermodeformable material. Wooden, chipboard, MDF and similar panels covered with a plastic laminate sheet are known. They are generally used for constructing furniture and in particular kitchen furniture, in which the exposed surfaces must possess definite aesthetic characteristics combined wi h resistance to rubbing and to attack by fatty and/or acid vapours. Such panels, which can have their exposed surface smooth or comprising ribs (grooves) even of a certain height (depth) are produced by applying a sheet of thermodeformable plastic material to this surface. The covering operation is completed by applying a further sheet to the opposite surface and strips of plastic covering material along the perimetral edges. A drawback of these panels is that the joint between the panel surface and edges presents a certain inevitable discontinuity which results both in a ugly separtion line and an incomplete covering and lack of protection of the underlying wooden substrate from the fatty and/or acid vapours normally present in the environments within which the panel is used. To obviate this drawback it has already been proposed to use a single thermodeformable plastic laminate sheet to simultaneously cover one surface and the edges of the wooden panel. the covering operation uses a press having a rigid surface and a heated surface of elastically yieldable material. The two surfaces can be moved relative to each other so as to press one against the other. During use, the panel to be covered plus the covering sheet treated with adhesive are placed between the two surfaces. The heat causes softening of said sheet and the pressure causes it to adhere to the flat surface and to the edges of the panel, to create covering continuity between the exposed surface and the edges. The particular nature of the operations involved ususally require certain precautions to be adopted, these consisting essentially of: — making sure that the panel is not kept adhering to the rigid surface of the press, but is instead kept separated from it by a spacer consisting essentially -of a panel of slightly smaller dimensions than those of the panel to be covered, in order to allow complete and correct adhesion of the plastic material to the panel edges, which would otherwise be only partial if the panel rested on said surface; - ~> - - keeping the plastic sheet softenec at the four corners of the panel to be covered during the pressing stage, in order to allow it to stretch during pressing instead of just being dragged, which would inevitably cause the laminate to crinkle at the panel corners. In practice this operation is effected by positioning four angular retainers at a short distance in front of the panel vertices to press the softened plastic sheet against the yieldable surface of the press and prevent it being dragged in a tangential direction. This covering operation is not normally carried out on single panels at time, which would result in very high costs, but instead is carried out on a plurality of panels simul aneously. For this purpose a so-called "membrane" press is used, comprising an upper fi ed platen and a lower mobile bed. The upper platen consists substantially of a thick metal plate, whereas the lower bed consists of a tray containing a heated liquid, generally water-, and is closed by a rubber membrane. To use this known type of press, at each pressing cycle a sheet of deformable plastic of dimensions compatible with the dimensions of the membrane is firstly placed on said membrane. The panels in a number and arrangement compatible - <+ - with the dimensions of the panels to be covered are then placed on said sheet together with the angular retainers in a position close to the panel vertices. Finally a spacer is placed on each panel so that the spacer edges are slightly to the inside of those of the panel . On ' operating the press all panels located on it are simultaneously covered, and remain joined together by the fact that the cover sheet is in one piece, they then being removed by a single operation of the press, and fed to the separation and finishing operations. This covering operation effected simultaneously on several panels has enabled the production rate to be considerably 'increased, while at the same time using the available equipment more intensely, however certain operational limits have appeared which it is the purpose of this invention to eliminate. One drawback of this known system is that the positioning of the laminate sheet on the lower bed of the press, the positioning of the panels and retainers on the sheet and the centering of the spacers on the panels must be done manually, resulting in considerable operational slowness and inaccuracy, which' can mean a large number of production re ects. An abject of the invention is to obviate this drawback by sustantially increasing the production of panels covered simultaneously on their exposed surface and their four edges. ~ A further object of the invention is to substantially reduce the personnel required for manually positioning the various elements required for the production cycle within the press. A further object of the invention is to obtain high • ] _-**, quality production, so substantially reducing rejects. These and further objects which will be more apparent hereinafter are attained according to the invention by an apparatus for covering a surface and the edges of panels of wooden material with a sheet of thermodeformable plastic 15 material, of the type for application to a press wi h a lower heated bed of elastically yieldable material and a rigid upper platen, the distance of which from the lower bed is variable between a maximum value which enables said sheet of thermodeformable material, the panels to be covered, the 20 retainers and the spacers to be interposed, and a ' minimum value at which the pressing -stage is effected, characterised by comprising: - a scisr frame removably attachable to the upper platen of the press; - a plurality of spacers applied to said frame, each spacer being provided with at least one hole connecting its lower surface to a suction circuit connected to said frame, and seal means surrounding said hole; - a conveyor for conveying thermodeformable plastic laminate sheets from a position outside said press to a position within it, said conveyor being provided with means for picking up and discharging said sheets; - a jig for positioning a plurality of panels to be covered, and provided with seats for these latter in positions corresponding with said spacers on said plate; and - means for transferring said positioning jig from the outside to the inside of the press and for raising it when inside the press, in order to bring the panels, located in their respective seats, into contact with the corresponding spacers. A preferred embodiment of the present invention is described in detail hereinafter with reference to the accompayiπg drawings in which: Figure 1 is a schematic plan view of a membrane press provided with the apparatus of the invention; Figure- Ξ is an enlarged cross-section therethrough on the l i nβ 11—11 of Figure 1 with the press in its open state; Figure 3 is an enlarged side view thereof on the line 111—111 of Figure 1; Figure ■•+ is an enlarged detailed . vertical sectional view showing the holes provided in the magnetizable , plate; Figure 5 is an enlarged partial vertical section through the apparatus on the line V-V of Figure 1 during the loading of the panels to be covered, and of the cover sheet; Figure 6 is the same view as Figure 5 but during the pressing stage; and Figure 7 is an enlarged partial vertical section on the line VII-VII of Figure 1 taken during the extraction of the panels covered by the press. As can be seen from the figures the apparatus according to the invention can be applied to a traditional membrane press, indicated overall by 1 and comprising a fi ed upper platen Ξ and a lower tray 3 containing a liquid 3' such as oil or water and closed upperly by a rubber membrane . The tray 3, which is provided with a traditional system for JlPStin ttlP liquid, not shown on the drawings for simplicity of representation, is supported by hydraulic cylinder-piston uni s 5 for its vertical movement alon guide columns 6 between lower position corresponding to the rest position, in which the press 1 is open for introduction of the panels 7 to be covered and the sheets 8 of thermodeformable laminate, and an upper position corresponding to the working position, in which said membrane 4 has been brought close to the upper platen 2 to press thereagainst the interposed panels 7 and laminate sheet 8. To the platen 2 there are applied a plurality of downwardly facing mushroom appendixes 9 to which a frame 10 of spacers 11 can be removably attached, as will be apparent hereinafter. The frame 10 consists substantially of a preferably wooden plate of dimensions substantially corresponding to those of the press platen 2, and to which the spacers 11 corresponding to the panels 7 to be covered are applied. For production rationalization reasons it is preferably for the various working cycles to be carried out on identical panels and hence with identical spacers, with the result that the number of frames 10 provided is equal to the number of types of panels to be covered, identical spacers 11 being applied to each frame in a number and arrangement compatible wi h the Q - dimensions of the frame 10 (and thus of the fixed platen Ξ of the press) and with the dimensions and shape of each panel. Each spacer 11 comprises at least one hole 1Ξ which traverses it through its entire thickness in a position corresponding wi h a further through hole 12' provided in the frame 10 and opening into a series of channels 13 provided in the platen 2 and connected to a suction system, not shown on the drawings. Along, but at a certain distance from, the edge of each spacer 11 there is provided a continuous seal gasket 14, which slightly projects from the spacer surface. For attaching the frame 10 to the platen 2 (see Figure 4) there are provided in the frame 10 recesses 15 which are each covered with a metal plate 16 comprising a slot having a width which varies from a maximum which just exceeds the head of the mushroom appendices 9, to a minimum which just exceeds the shank of said appendices. The plates 16 are provided in the frame 10 to correspond with the positions occupied by the mushroom appendices 9 in the fixed platen 2. Retainers 17 are also applied to the frame 10. These consist of elongate blocks of wood fixed to the frame 10 at a short distance from the spacers 11. They can be applied to correspond with the four vertices of each spacer, and in this case they are of L-shape, or they can be applied along the outer edge of just the outer spacers, in which case they can be straight, except for those at the corners, which are of __- shape. The apparatus according to the invention also comprises a feeder for feeding both the panels 7 to be covered and the sheets -8 of thermodeformable plastic laminate for the covering. This feeder comprises a fi ed, framework 18 positioned to the side of the press 1, a feed line for the plastic laminate sheets 8 and a feed carriage 19 mobile away from and towards the press 1. The plan dimensions of said carriage 19 substantially correspond to those of said press 1. In i s essential elements, the feed line for the sheets 8 comprises: - fixed to the framework 18, a pair of supports 20 for a reel 21 of thermodeforma le plastic web pretreated wi h suitable adhesive; - a radiation heater 22 for removing the curvature from said web before it reaches the feed carriage 19; and - a transverse web cutter 23 comprising a chain taut transversely on the unwinding web, and a pair of blades 24 fixed at equidistant points thereon. The carriage 19 is provided on the prolongation of this fθβd line and is supported by the framework 18. It consists substantially of a metal frame slidable substantially along guides fi ed to the framework 18 and tα the press 1, between a position in which it is totally contained within said framework and a position in which it is totally contained within said press 1. The frame of the carriage 19 is provided with a plurality of suckers 25 connected to a suction circuit, and s mobile in a vertical direction between a lower position in which it grips a sheet of thermodeformable laminate 8 from the feed line downstream of the cutter 23, and an upper position raised above said feed line. ■ These vertical movements are obtained by any conventional means, preferably pneumatic or electrical. The top of the frame of the carriage 19 is provided wi h supports 26 for a jig 27, consisting essentially of a blockboard panel in which seats are provided for the panels 7 to be covered. The apparatus according to the invention also comprises an extraction line for the covered panels. In the illustrated embodiment this extraction line comprises a framework 28 situated on the opposite side of the press 1 to the framework - IE - 18. As in the case of the framework 18, the framework 28 is also provided with a pair of horizontal guides along which carriage 29 slides between a position in which it is totall housed within the open press 1, and a position totall outside it. In the carriage 29 there is mounted a conveyor belt 30, mobile - in a direction perpendicular to the direction o movement of the carriage and extending between two en rollers 31. The operation of the apparatus according to th invention is as follows: The operation of the apparatus according to th invention is as follows: after defining the type of panels 7 to be covered, th corresponding spacer frame 10 is mounted. For this purpose the frame 10 is firstly placed on the support 26 of th carriage 19 and is transferred by this into the press 1 , to position exactly lying below i s upper fixed platen 2. Th surface of the carriage 19 is then raised until the mushroo appendices 9 of the platen 2 engage in the correspondin metal plates 16 of the frame 10. The frame 10 is then move horizontally relative to the platen 2 to cause the appendice 9 to -bayonet-engage the slot of the plates 16 to thu securely attach the frame 10 to the platen Ξ . This horizontal movement can be effected either by the carriage 19 itself or, preferably, by screw pushers applied to the platen 2 and acting on the edge of the frame 10. These pushers are not shown on the drawings for simplicity of representation. Their purpose is also to set the position of said frame with maximum precision, for the reasons given hereinafter. After the frame 10 has been correctly secured in position, the two components should be sealed together to enable the suction created in the channels 13 of the platen 2 to be transmitted to the holes 12 of each spacer 11. This is done by sealing the separation line between the two contacting edges, for example with adhesive tape. That jig 27 corresponding to the particular frame 10, ie the jig comprising seats for panels 7 lying exactly below the spacers 11 -when the carriage 19 is in its end-of-travel position within the press, is then positioned on the supports 26 of the carriage 19. The facility for effecting even minimum displacements of the frame 10 makes it possible in all cases to obtain precise relative positioning. After carrying out this preparatory work and heating the liquid 3' contained in the tray 3 to the required temperature, the press is ready for operation. A length of thermoplastic material corresponding to the length of the frame 10 is firstly unwound from the reel 21 and the heater 5 22 is simultaneously powered, so as to at least approximately straighten it. The cutter 23 is then operated to separate from the material web the sheet 8 which is already lying below the suckers 25. One or more operators simultaneously load a panel 7 to be covered into each seat of the jig 27. 10 On termination of this stage a command is fed to cause the suckers 25 to descend onto the sheet 8 and open their connection to the suction circuit, so as to grip the sheet 8 and raise it. The carriage 19 is then advanced until it reaches its position within the press 1. Having reached this, ■ ^-5 the suction effect of the suckers is interrupted with the result that they allow the sheet 8 to fall onto the membrane 4, after which the jig 27 is raised until each panel 7 adheres to the spacer 11 of frame 10. Because of the correct relative positioning between the 20 frame 10 and the jig 27, each panel 7 is perfectly centered against the overlying spacer 11, and can be secured to it by suction. After the carriage 19 has been again lowered and has • -f i h& pf°-≡s t , t e tray 3 is raised until the membrane 4 presses the sheet 8 with high pressure against the panels 7 and retainers 17, so implementing the covering operation. On termination of the pressing stage, the tray 3 is made to descend but without interupting the suction effect on the spacers 11, which in this manner continue to retain the already covered panels 7. After the descent of the tray 3, the press 1 receives the carriage 29, onto which the panels 7 retained together by the single sheet 8 fall following interruption of the suction on the spacers 11. Practically it may occur that the membrane 4 can lacerate by wear and also due to the probably break of the laminate sheet 8 during its deformation. In this case, in order to avoid that the liquid 3', which unavoidably enters the suction channels 13, can damage the vacuum pump, in the suction circuit there are provided filters or like to capture this liquid. When the carriage 29 has left the press 1 , . the conveyor belt 30 is operated to transfer the covered panels to the other separation and/or finishing stations, and the system is ready to repeat the operating cycle on a new series of panels 7 which in the meanwhile have been arranged on the feed line. From the aforegoing it is apparent that the apparatus according to the invention enables wooden panels to be covered with thermodeformable plastic material at a high production rate, with considerable operational precision and thus with a very low percentage of rejects, and with a working cycle which can be highly automated, with the only exception of the positioning of the panels 7 in the corresponding seats in the jig 27, an operation however which can be effected by one person.

Claims: C L I M S 1. An apparatus for covering a surface and the edges of panels of wooden material with a sheet of thermodeformable plastic material, of the type for application to a press with a lower heated bed of elastically yieldable material and a rigid upper platen, the distance of which from the lower bed is variable between a maximum value which enables said sheet of thermodeformable material, the panels to be covered, the retainers and the spacers to be interposed, and a minimum value at which the pressing stage is effected, characterised by comprising: - a frame (10) of spacers (11) removably attachable to the upper platen (2) of the press (1); - a plurality of spacers (11) applied to said frame (10), each spacer (11) being provided with at least one hole (12) connecting its lower surface to a suction circuit (13) connected said frame (10), and seal means (14) surrounding said hole; - a conveyor (19) for conveying thermodeformable plastic laminate sheets (8) from a position outside said press (1) to a position within it, said conveyor being provided with means (25) for picking up and discharging said sheets (B); - a jig (27) for positioning a plurality of panels (7) to be covered, and provided with said spacers (11) on said frame (10); and - means (19) for transferring said positioning jig (27) from the outside to the inside of the press (1) and for raising it when inside the press, in order to bring the panels (7), located in their respective seats, into contact with the corresponding spacers (11). 2. An apparatus as claimed in claim 1, characterised in that the attachment between the upper platen (2) of the press ■ -■ ■ and the frame (10) containing the spacers (11) is obtained by mushroom appendices (9) and slotted plates (16) provided in the frame and bayonet-engageable with each other. 3. An apparatus as claimed in claim 1, characterised in that each spacer (11) comprises at least one through hole (12) connected " to a suction network (13) via the frame (10). 4. An apparatus as claimed in claim 1, characterised in that the seal means surrounding said hole (12) consist of a continuous perimetral gasket (14) partially projecting from the lower surface αf the corresponding spacer (11). 5- A n apparatus as claimed in claim 1, characterised in that the retention elements (17) are applied to the frame (10) at least in positions corresponding with the outer edge of the- spacers (11). 6. An apparatus as claimed in claim 1, characte ised in that there are associated with the conveyor (19) an unwinder for unwinding said sheets (8) from a reel (21) and a cutter (23) for separating the sheets (8) from the web unwound from said reel. 7. An apparatus as claimed in claim 1, characterised in that a heater (22) is interposed between the reel (21) and the cutter (23) to remove curvature from the web unwound from said reel . 8. An apparatus as claimed in claim 6, characterised in that the cutter (23) consists substantially of an endless chain extending tautly transversely to the web of thermodeformable material unwound from said reel (21), and at least one blade (24) applied to said chain. 9. An apparatus as claimed in claim 1, characterised by comprising a framework (IB) to the side of the press (1) and a carriage .(19) mobile between a position within and a position outside said press (1), said carriage being provided lowerly with a plurality of suckers (25) connected to a suction network for picking up and transferring each sheet from the framework (18) to the lower bed (3) of the press, and a plurality of supports (26) for said jig (27). 10. An apparatus as claimed in claim 9, characterised in that members for vertically moving said suckers (25) and said supports (26) are associated with the carriage (19). 11. An apparatus as claimed in claim 1, characterised by comprising a member (29) for extracting from the press (1) the panels (7) covered with the sheet (8) on termination of the covering stage. 12. An apparatus as claimed in claim 11, characterised in that the extractor member (29) comprises a framework (28) located to the side of the press (1) and a carriage (29) mobile between a position outside and a position within said press and provided with a conveyor belt (30) for transferring the total covered panels (7) to the subsequent working stages.

Inventors: BERGAMO LUCIANO, BERGAMO, LUCIANO
Applicants: 3B SPA, 3B S.P.A.
Application year: 1990
Main classification: B30B15
IPC codes: B29C31, B29C33, B29C43, B29C51, B29C63, B30B15