WO2006007641A1 - Apparatus for applying a veneer material to an edge surface of a planar panel - Google Patents

Abstract

An apparatus (1) for applying a veneer material to an edge surface (3) of a planar panel (5), the apparatus including: a heating member (6) for contacting at least a portion of the veneer material and transferring heat thereto, such that in turn at least a portion of an adhesive located between the veneer material and the edge surface (3) is heated; and a heat resistant member (8) for contacting at least a portion of the veneer material after the adhesive is heated such that a force applied by the user to the apparatus (1) is transferred to the veneer material to thereby adhere the veneer material to the edge surface (3), the heat resistant member (8) having a channel (17) with at least a portion of the heating member (6) being located within the channel (17).

Description

APPARATUS FOR APPLYING A VENEER MATERIAL TO AN EDGE

SURFACE OF A PLANAR PANEL FIELD OF THE INVENTION

The present invention relates to an apparatus for applying a veneer material to an edge surface. More particularly, the present invention relates to an apparatus for applying melamine to an edge surface of a planar panel as well as a method of applying melamine using the apparatus. BACKGROUND OF THE INVENTION

Veneer material such as melamine is used in a wide variety of applications to cover planar panels. For example, it is commonly used in kitchens to cover the planar panels used in bench tops, cupboard doors and shelving. Melamine is usually purchased from a supplier in large sheets which are then cut to an appropriate size to cover the face of the planar panel. In order to cover the edge surface of a planar panel, a roll of melamine with a width approximately corresponding to the width of the edge surface is utilised after being cut to the appropriate length.

In order to adhere melamine to the desired panel some form of heating implement is required to heat the glue on the melamine to a temperature appropriate for adhesion to occur. The heating implement typically used for this procedure is a conventional household iron and/or a hot air gun.

Following the application of heat, pressure needs to be applied to the melamine to ensure that the melamine properly adheres to the panel being covered. Typically, some form of hand-held block material (for example, a cork block) is used to apply the required pressure. The installer thus needs to manipulate two separate tools - for example, an iron and a cork block. This does not present too much difficulty when applying sheet melamine to a face surface of a panel, where a tool can be held in each hand, but presents significant difficulty when applying a long strip of melamine to an edge surface of a panel, where the melamine itself must be held in the correct position on the edge surface whilst it is being heated and pressure is applied. Clearly, the installer does not have enough hands. In order to guide the positioning of the melamine strip with one hand, he must alternate between the iron and cork block with the other hand, at the same time being careful to safely set down the hot iron between each use. This operation is awkward and hazardous.

Alternatively, the conventional household iron is used not only as the heating implement but also as a means by which the user can impart pressure to the melamine. However, a problem with this approach is that the iron can still be hot when it is being used to impart pressure to the melamine. Accordingly, the user has to be careful not to overheat and damage the melamine which can result if the iron is held in the same position on the melamine for too long. A further problem in using an iron as a means to impart pressure is that if the iron is still hot when the pressure is applied the adhesive will not harden. Accordingly it is necessary to allow the iron to cool prior to using the iron as a tool to apply pressure.

A further problem in using a conventional household iron to apply melamine is that its relatively large heating surface is not always suitably shaped for the task. Whilst a household iron can generally be utilised on large planar panels they can be problematic to use in other circumstances. For example, when applying melamine to an edge surface of a planar panel, particularly if the edge surface is curved. Further, if the edge surface of the panel is located in a confined space and is thereby difficult to access, a conventional household iron may not be able successfully manoeuvre along the edge surface.

Accordingly, an object of the present invention is to provide an apparatus which overcomes or ameliorates at least one of the problems associated with applying melamine to an edge surface of a planar panel.

Any discussion of documents, devices, acts or knowledge in this specification is included to explain the context of the invention. It should not be taken as an admission that any of the material formed part of the prior art base or the common general knowledge in the relevant art in Australia or other countries on or before the priority date of the claims herein. SUMMARY OF THE INVENTION

In accordance with the present invention there is provided an apparatus for applying a veneer material to an edge surface of a planar panel. The apparatus includes a heating member for contacting at least a portion of the veneer material and transferring heat thereto. In turn at least a portion of an adhesive located between the veneer material and the edge surface of the planar panel is heated. The apparatus further includes a heat resistant member for contacting at least a portion of the veneer material after the adhesive is heated such that a force applied by the user to the apparatus is transferred to the veneer material to thereby adhere the veneer material to the edge surface. The heat resistant member includes a channel with at least a portion of the heating member being located within the channel.

Preferably, the heating member is located substantially within the channel, and the heating member and the heat resistant member are both substantially elongate and extend along the entire length of the apparatus. The heat resistant member may include first and second protruding portions, wherein the protruding portions have side walls which form side walls of the channel. Preferably, the first and second protruding portions extend along the entire length of the apparatus.

Advantageously, the channel with the heating member located therein extends along the entire length of the apparatus. This arrangement permits the entire length of the channel to be filled with the edge surface of the planar panel during the heating of the adhesive.

In a preferred embodiment of the invention, the heating member is an elongate plate which is located adjacent to a bottom of the channel. Preferably, an air gap is provided between the elongate plate and the bottom of the channel. The channel is preferably open at each end with one end of the elongate plate extending beyond one end of the channel. The other end of the elongate plate preferably includes a lip member which is located adjacent to the other end of the channel.

In accordance with a particularly preferred embodiment, the first and second protruding portions each have a planar bottom surface. Each planar bottom surface is configured to contact the veneer material and transfer a force applied by the user to the apparatus, to the veneer material. Further, each planar bottom surface is preferably provided with tapered end sections.

In accordance with a further aspect of the invention there is provided a method of applying a veneer material to an edge surface of a planar panel using the above described apparatus. The method includes the step of firstly contacting at least a portion of the veneer material with at least a portion of the heating member such that heat is transferred to at least a portion of the adhesive located between the veneer material and the edge surface. The second step includes contacting at least a portion of the veneer material with at least a portion of the heat resistant member whilst applying a force to the apparatus in a direction towards the edge surface. As a result, the applied force is transferred to the veneer material via the heat resistant member to thereby secure the veneer material to the edge surface. BRIEF DESCRIPTION OF THE DRAWINGS

Further benefits and advantages of the present invention will become apparent from the following description of a preferred embodiment of the invention. The preferred embodiment should not be considered as limiting any of the statements in the previous section. The preferred embodiment will be described with reference to the following Figures in which:

Figure 1 is a perspective view of the apparatus according to an embodiment of the invention.

Figure 2 is a top view of the apparatus of Figure 1 ;

Figure 3 is a bottom view of the apparatus of Figure 1 ;

Figure 4 is a side view of the apparatus of Figure 1 ;

Figure 5 is an end view of the apparatus of Figurei ;

Figures 6 to 11 illustrate the apparatus of Figure 1 with the heating member in contact with the edge surface of a planar panel;

Figures 12 to 17 illustrate the apparatus of Figure 1 with the heat resistant member in contact with the edge surface of a planar panel. DESCRIPTION OF PREFERRED EMBODIMENT

The following preferred embodiment of the invention relates specifically to an apparatus for applying melamine to an edge surface of a planar panel. However as the invention is applicable to the application of any veneer material, the following description in relation to the application of melamine should not be considered as limiting the scope of the invention to only the application of melamine.

With reference to the accompanying drawings there is shown an apparatus 1 for applying melamine to an edge surface 3 of a planar panel 5. The apparatus 1 includes a heating member 6 and a heat resistant member 8. The heat resistant member 8 has first and second protruding portions 11 , 13 which each have a side wall 15 which define the walls of a channel 17.

The first and second protruding portions 11 , 13 and the channel 17 therebetween extend along the entire length of the apparatus 1. The first and second protruding portions 11 , 13 each have a planar bottom surface 19 with a tapered end section 21 at each end. The heat resistant member 8 further includes an upper section 23 to which the first and second protruding portions 11 , 13 are attached.

The heating member 6 includes an elongate plate 7 which is located adjacent to a bottom 25 of the channel 17. The elongate plate 7 extends along the entire length of the channel 17. The heating member 6 further includes a plurality of spacers which space the elongate plate 7 away from the bottom 25 of the channel 17 such that an air gap is provided between the bottom 25 of the channel 17 and the elongate plate 7. The spacers of the heating member 6 extend through the upper section 23 of the heat resistant member 8 into an internal enclosure formed by the upper section 23.

The elongate plate 7 includes a lip member 29 at one end. The lip member 29 has a diameter of approximately 10mm which assists the elongate plate 7 to access edge surfaces 3 having tight turns and sweeping curves. The other end of the elongate plate 7 extends beyond the end of the channel 17. To prevent accidental contact with the lip member 29 by a user of the apparatus the upper section 23 includes a protective protuberance 30 which extends over the top of the lip member 29. Similarly, to prevent accidental contact with the portion of the elongate plate 7 which extends beyond the end of the channel 17 the upper section 23 includes a protective cover 32 which extends over the top of the elongate plate 7.

The apparatus 1 is connected to mains power such that heat is provided by a heating element to the elongate plate 7 in a manner similar to a conventional household iron. The power supplied to the apparatus may also be used to operate a light source located on the upper section 23 which emits light to indicate when the apparatus 1 is receiving power. A heat control dial 31 is also located on the upper section 23 to allow the temperature of the elongate plate 7 to be adjusted. The heat control dial 31 can select a temperature within the range of 0°C to approximately 300°C for the elongate plate 7. The elongate plate 7 is made of a composite magnesium alloy similar to that used for some conventional household irons. The upper section 23 of the heat resistant member 8 is attached to a handle 33 which permits the apparatus 1 to be grasped and manoeuvred by the user in the desired manner.

Figures 6 to 11 illustrate the apparatus 1 being used to heat an adhesive located between a strip of melamine material located on an edge surface 3 of a planar panel 5. The elongate plate 7 is approximately 20mm in width which substantially corresponds with the thickness of most planar panels 5. Accordingly, adhesive located across the thickness of the edge surface 3 of the planar panel 5 can be appropriately heated without side ways movement of the apparatus 1 across the edge surface 3. The lip member 29 provided at one end of the elongate plate 7 permits contact with tight internal corners as illustrated in Figure 6, and sweeping curved edge surfaces, as depicted in Figure 9.

The portion of the elongate plate 7 which extends beyond the end of the channel 17 permits the heating member 6 to contact edge surfaces 3 at butt joins between two adjacent planar panels 5, as depicted in Figure 8 and 10. As the channel 17 is open at each end, the elongate plate 7 of the heating member 6 is able to fill the entire length of the channel 17 with a section of the edge surface 3 during the heating of the adhesive. In addition, as the heating member 6 is located adjacent to the bottom 25 of the channel 17 the apparatus 1 can rest on the planar bottom surface 19 of the heat resistant member 8 during periods of non-use, without contact being made with the heating member 6. Accordingly, the unit can be placed on a bench, table, etc without being switched off.

Figures 12 to 17 illustrate the first and second protruding portions 11 , 13 engaging with an edge surface 3 of the planar panel 5 to permit the user to apply pressure to the apparatus 1 via the handle 33 to thereby assist the melamine to adhere to the edge surface 3. In a manner similar to the lip member 29, the tapered end sections 21 of the first and second protruding portions 11 , 13 permit the heat resistant member 8 to engage a wide variety of curved edge surfaces 3, such as tight internal corners as depicted in Figure 12 and sweeping curves as illustrated in Figure 15. The first and second protruding portions 11 , 13 are preferably constructed of a heat resistant plastic material which will not damage the edge surface 3 as the planar bottom surface 19 of the first and second protruding portions 11 , 13 engages with the edge surface 3.

As the present invention may be embodied in several forms without departing from the essential characteristics of the invention, it should be understood that the above described embodiment should not be considered to limit the present invention but rather should be construed broadly. Various modifications and equivalent arrangements are intended to be included within the spirit and scope of the invention. For example, the elongate plate 7 of the heating member 6 may be curved, rather than straight, so as to facilitate applying the veneer material to an edge surface having a sweeping curve. Similarly, the heat resistant member 8 may be provided with curved protruding portions to facilitate the application of pressure against a curved edge surface.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An apparatus for applying a veneer material to an edge surface of a planar panel, the apparatus including: a heating member for contacting at least a portion of the veneer material and transferring heat thereto, such that in turn at least a portion of an adhesive located between the veneer material and the edge surface is heated; and a heat resistant member for contacting at least a portion of the veneer material after the adhesive is heated such that a force applied by the user to the apparatus is transferred to the veneer material to thereby adhere the veneer material to the edge surface, the heat resistant member having a channel with at least a portion of the heating member being located within the channel.

2. An apparatus as claimed in claim 1 wherein the heating member is located substantially within the channel.

3. An apparatus as claimed in claim 1 or 2 wherein the heating member and the heat resistant member are substantially elongate and extend along an entire length of the apparatus.

4. An apparatus as claimed in claim 3 wherein the heat resistant member includes a first and second protruding portion and wherein side walls of the first and second protruding portions form side walls of the channel.

5. An apparatus as claimed in claim 4 wherein the first and second protruding portions extend along the entire length of the apparatus.

6. An apparatus as claimed in claim 5 wherein the channel with the heating member located therein extends along the entire length of the apparatus such that the entire length of the channel can be filled with the edge surface of the planar panel during heating of the adhesive.

7. An apparatus as claimed in claim 6 wherein the heating member includes an elongate plate located adjacent a bottom of the channel.

8. An apparatus as claimed in claim 7 wherein an air gap is provided between the elongate plate and the bottom of the channel.

9. An apparatus as claimed in claim 8 wherein the channel is open at each end, with one end of the elongate plate extending beyond one end of the channel.

10. An apparatus as claimed in claim 9 wherein the other end of the elongate plate includes a lip member located adjacent the other end of the channel.

11. An apparatus as claimed in any one of claims 4 to 10 wherein the first and second protruding portions each have a planar bottom surface configured to contact the veneer material and transfer said force applied by the user to the apparatus, to the veneer material.

12. An apparatus as claimed in claim 11 wherein the first and second bottom surfaces have tapered end sections.

13. A method of applying a veneer material to an edge surface of a planar panel using the apparatus as claimed in any one of the preceding claims, the method including the steps of: contacting at least a portion of the veneer material with at least a portion of the heating member such that heat is transferred to at least a portion of an adhesive located between the veneer material and the edge surface; and contacting at least a portion of the veneer material with at least a portion of the heat resistant member whilst applying a force to the apparatus in a direction towards the edge surface such that the force applied is transferred to the veneer material via the heat resistant member to thereby secure the veneer material to the edge surface.

14. An apparatus substantially as herein before described with reference to the accompanying drawings.

15. A method substantially as herein before described with reference to the accompanying drawings.