Panel decoration

Abstract: A raised and fielded panel and a sheet of decorative material are brought together so that the sheet overlies the raised and fielded side of the panel and at least one of the raised and fielded side of the panel or the obverse face of the sheet of decorative material has a coating of a heat activatable adhesive, with the adhesive properties of the composition being activatable at or above about 80°C. The sheet of decorative material is then pressed against the panel at a temperature of from about 90°C to about 170°C and at a pressure of from about 1 to 6 bars for from about 5 to about 25 seconds. A decorative surface is formed on the raised and fielded side of the panel in which the adhered sheet follows the contours of the panel. The advantage of the method is that it can avoid wrinkling of the sheet of decorative material.

Description: The present invention relates to the decoration of panels and, in particular, to a method of applying a decorative finish to a raised and fielded door or like panel. In order to conserve forests it is becoming increasingly undesirable to produce solid wood products. For example, solid wood mahogany products are becoming unfashionable with all true conservationists because of the effect on tropical rain forests caused by deforestation to supply mahogany wood. Moreover, equally good products can be produced from wood waste formed into, for example, medium density fibreboard by laminating to the outside surface thereof a decorative finish applied as a sheet of material such as paper, plastics or a paper/plastics laminate. Thus, it is known to apply a decorative finish to door or like panels using various kinds of sheet material and a heat activatable coating on the panel. The panel and sheet material typically are pressed together at a temperature at which the coating is activated and the thus-formed laminate then cooled to provide a decorated panel. While the above technique is generally satisfactory difficulties can arise (a) with the use of paper sheet material and/or (b) where the panel is a raised and fielded panel with fielding varying in at least two directions at each corner of the panel. In such circumstances wrinkling can occur, especially at each corner and the decorative finish can be spoiled. Within the above context we have now found surprisingly that wrinkling of the sheet material especially at each corner can be avoided by a careful selection of the operating conditions, generally time, temperature and pressure. Accordingly, the present invention provides a method of applying a decorative finish to a raised and fielded panel, which method comprises bringing together the panel and, as a decorative finish, a sheet of wrinklable furniture foil, said furniture foil comprising a sheet of decorative paper material comprising paper sheet and resin-impregnation, the panel and furniture foil being brought together so that the foil overlies the raised and fielded side of the panel, there being for adhesion of said furniture foil to said panel a coating of a heat-activatable adhesive composition between the panel and said furniture foil, and pressing said furniture foil against the panel at an elevated temperature and pressure to activate said adhesive composition and so as to form by said foil an unwrinkled decorative surface on the raised and fielded side of the panel in which the adhered furniture foil follows the contours of the panel, the decorative paper material comprising the paper sheet and the resin to a total combined weight thereof of not more than 140gsm, and said paper-thin wrinklable furniture foil optionally including as part thereof an unstructured anti-telegraphing layer in the form of a fleece backing to said decorative paper material sheet, characterized in that the method is performed whilst complying with the following parameters:- (i) the elevated temperature at which said pressing of said furniture foil against the panel is effected is at least about 90°C and not more than about 170°C, (ii) the fielding of the panel reduces the thickness of the panel through shallow curvature of the fielding and defines a relatively raised panel portion enclosed by the fielding in such manner that the fielding frames said relatively raised panel portion in fielding lengths unified at arissed corner junctions of the fielding, the fielding curvature being curvature to a radius of about 45 mm or more, (iii) the adhesive composition is applied by spraying and to the raised and fielded side of the panel, (iv) the elevated pressure at which said pressing of said furniture foil against the panel is effected is from about 1 to about 6 bars, (v) the duration of said pressing of said furniture foil against the panel is a period of from about 5 to about 25 seconds, and (vi) the adhesive composition is one which is heat-activatable at temperatures in the range from about 80°C to the pressing temperature. The method of the invention is particularly useful when applied to doors or the like in which a panel is framed by a framing element at each side edge and the abutting ends of the elements are mitred. Typically, in such an arrangement the panel may comprise a medium density fibreboard and the framing elements may comprise a laminated profile. Especially the framing elements may comprise a chipboard or medium density fibreboard laminated profile, which is already coated or laminated before the method of the invention is carried out. Thus, typically the profiles may be chip board profiles wrapped in decorative sheet material, the sheet material being chosen to match or contrast with that provided by the sheet material to be adhered to the panel. In the method of the invention the heat activatable composition may be any composition activatable at or above about 80°C and compatible with the panel. Preferably, the composition comprises a polyvinylacetate cross-linking adhesive. Alternatively, however, or additionally, the composition may comprise polyurethane. Prior to carrying out the method of the invention the said composition is applied to the panel face of the obverse face of the decorative sheet by any suitable means such as by brushing or roller coating. Preferably, however, the composition is applied to the panel face by spraying. The decorative material is a paper sheet, which may be a laminate of paper and a a fleece backing substrate. In the method of the invention the steps used to decorate the panel are particularly applicable when the panel fielding varies in at least two or three directions at each corner of the panel. Furthermore, the method is preferably one wherein the panel and the sheet of decorative material are brought together in a membrane (or bag) press. In carrying out the method of the invention the coated panel face and the decorative material are brought together under selected conditions within the above given ranges in a press. Then, if the pressing is not satisfactory and wrinkles result (this may be due to varying ambient temperature) the pressing is repeated at a higher temperature nearer the upper limit of about 170°C -preferably at or above about 135°C. Next, if the pressing remains unsatisfactory the pressing time and/or the pressing pressure is/are increased until a satisfactory result is obtained. It is, of course, to be understood that the temperature mentioned herein is the indicated temperature of the press or pressing conditions used, that is to say by indicated temperature we mean the temperature indicated by the sensor display on the press used. Also, it is to be understood that for reasons of cost the temperature of pressing should be kept as low as possible. The method of the invention will now be described in detail by way of example only with reference to the following specific Examples. Example 1 A medium density fibreboard raised and fielded door panel having the following dimensions: Width: 40 cm Length: 60 cm Fielding: Panel thickness reduced from 9 mm to 5 mm through a shallow curve of radius 45 mm was coated on its outer fielded face with a polyurethane Helmutin-type adhesive available under the trade mark Helmipur 34333, at a coating weight of 70 to 80 gsm. The coated panel face was then covered by an 80 gsm resin-impregnated paper decorated with a wood grain finish on the paper surface not adjacent the coated face and the whole pressed in a membrane (or bag) press without vacuum at about 140°C for about 12 seconds at a pressure of about 2.5 bar. The resulting panel was of a good finish and there were no wrinkles at the fielded corners. Example 2 The method of Example 1 was repeated except that the door panel was 30 cm wide and 61 cm long. Also, the polyvinylacetate adhesive was a standard laminating grade of PVA glue and the decorative sheet material was a 140 gsm resin-impregnated paper provided with a fleece backing. The whole was pressed in a membrane (or bag) press without vacuum at about 130°C for about 20 seconds at a pressure of about 2.5 bar. Again, the resulting panel was of good finish without wrinkling. It is, of course, to be understood that the invention is not limited to the specific details given above and that numerous variations may be made without departing from the scope of the claims which follow.

Claims: A method of applying a decorative finish to a raised and fielded panel, which method comprises bringing together the panel and, as a decorative finish, a sheet of wrinklable furniture foil, said furniture foil comprising a sheet of decorative paper material comprising paper sheet and resin-impregnation, the panel and furniture foil being brought together so that the foil overlies the raised and fielded side of the panel, there being for adhesion of said furniture foil to said panel a coating of a heat-activatable adhesive composition between the panel and said furniture foil, and pressing said furniture foil against the panel at an elevated temperature and pressure to activate said adhesive composition and so as to form by said foil an unwrinkled decorative surface on the raised and fielded side of the panel in which the adhered furniture foil follows the contours of the panel, the decorative paper material comprising the paper sheet and the resin to a total combined weight thereof of not more than 140gsm, and said paper-thin wrinklable furniture foil optionally including as part thereof an unstructured anti-telegraphing layer in the form of a fleece backing to said decorative paper material sheet, characterized in that the method is performed whilst complying with the following parameters:- (i) the elevated temperature at which said pressing of said furniture foil against the panel is effected is at least about 90°C and not more than about 170°C, (ii) the fielding of the panel reduces the thickness of the panel through shallow curvature of the fielding and defines a relatively raised panel portion enclosed by the fielding in such manner that the fielding frames said relatively raised panel portion in fielding lengths unified at arissed corner junctions of the fielding, the fielding curvature being curvature to a radius of about 45 mm or more, (iii) the adhesive composition is applied by spraying and to the raised and fielded side of the panel, (iv) the elevated pressure at which said pressing of said furniture foil against the panel is effected is from about 1 to about 6 bars, (v) the duration of said pressing of said furniture foil against the panel is a period of from about 5 to about 25 seconds, and (vi) the adhesive composition is one which is heat-activatable at temperatures in the range from about 80°C to the pressing temperature. A method according to claim 1, wherein the panel is framed by a framing element at each side edge and the abutting ends of the elements are mitred. A method according to claim 1 or claim 2, wherein the panel comprises a medium density fibreboard. A method according to claim 2 or claim 3, wherein the framing elements comprise a laminated profile. A method according to Claim 4 wherein the laminated profile is a chipboard or medium density fibreboard laminated profile. A method according to any one of the preceding claims, wherein the composition comprises a polyvinylacetate cross-linking adhesive. A method according to any one of the preceding claims, wherein the composition comprises a polyurethane. A method according to any one of the preceding claims, wherein the panel fielding varies in at least two directions at each corner of the panel. A method according to any one of the preceding claims, wherein the panel and sheet of decorative material are brought together in a membrane press.

Inventors: AUDRITT MICHAEL LEONARD, AUDRITT VINCENT MARK, AUDRITT, MICHAEL LEONARD, AUDRITT, VINCENT MARK
Applicants: AUMAC LTD, AUMAC LIMITED
Application year: 1991
Main classification: B44C5
IPC codes: E04F13, B44C5