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WO2009148851A1 - Panneau de bureau - Google Patents

Panneau de bureau Download PDF

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Publication number
WO2009148851A1
WO2009148851A1 PCT/US2009/044927 US2009044927W WO2009148851A1 WO 2009148851 A1 WO2009148851 A1 WO 2009148851A1 US 2009044927 W US2009044927 W US 2009044927W WO 2009148851 A1 WO2009148851 A1 WO 2009148851A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
layer
tool
structural layer
edge
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2009/044927
Other languages
English (en)
Inventor
Julie L. York
Kenneth Assink
Sherry L. Graham
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Illinois Tool Works Inc
Original Assignee
Illinois Tool Works Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Illinois Tool Works Inc filed Critical Illinois Tool Works Inc
Publication of WO2009148851A1 publication Critical patent/WO2009148851A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/326—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with corrugations, incisions or reliefs in more than one direction of the element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2479/00—Furniture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/12—Deep-drawing

Definitions

  • the present invention relates to office panels, and more particularly to an apparatus and method for producing office panels with a three dimensional surface pattern.
  • Office panels are well known, for instance, for use as privacy screens, cubicle dividers, and other organizational features for the office environment, and in some cases in home offices or other commercial or residential applications. These panels typically include a front, visible surface attached to a structural backer. The visible surface is commonly a decorative fabric, and the backer may be foam, fiberboard, fiberglass or another rigid or semi-rigid material attached to the visible surface with an adhesive. In some cases, office panels may have additional functional characteristics, such as for use as a tackboard.
  • three dimensional panel includes a visible outer layer, a heat activated adhesive scrim layer and a structural non-woven polyester fiber layer.
  • the three layers are heated in an oven to activate the adhesive and heat the polyester fiber to a moldable temperature, and then moved to a mold assembly.
  • the mold assembly typically formed from aluminum, includes an upper mold and a lower mold that can be pressed together to mold the heated layer assembly.
  • At least one of the molds has a surface shaped to the desired shape of the panel surface, and the molds are pressed together to form the layers assembly into the desired shape.
  • the molded assembly is cut with a die to a desired size.
  • Final edge preparations are often done by hand to wrap the edges of the visible layer around the sides of the structural layer and adhere them to the structural layer.
  • the embodiments of the present invention provide a panel having a main portion with a three-dimensional surface contour and an integral, finished edge portion extending from the main portion.
  • the panel includes a structural layer and a visible outer surface layer.
  • the structural layer has a main portion including an upper surface and a lower surface, and a peripheral edge portion extending downwardly from the main portion.
  • the structural layer is molded such that the upper surface of the main portion has a three-dimensional surface contour pattern.
  • the visible outer later is attached to the upper surface of the main portion of the structural layer.
  • a first portion of the outer layer extends over the upper surface of the structural layer and is conformed to the surface contour pattern of the structural layer.
  • the outer layer has an edge portion that extends from the first portion. The edge portion covers substantially all of the edge portion of said structural layer to form an integral finished edge on the panel.
  • the panel with finished edge is formed by the steps of (1) providing a first tool having an upper surface, a side edge, and a cutting surface, the upper surface spaced above the cutting surface; (2) providing a second tool having a perimeter die blade; (3) placing a heated panel blank between the first tool and the second tool, the panel blank having a structural layer, an outer surface layer, and an adhesive layer, the panel blank having a main portion, and an edge portion; and (4) moving at least one of the first tool and the second tool to compress the main portion of the panel blank between the first tool and the second tool, and to contact the outer surface layer with the perimeter die blade, the perimeter die blade drawing the edge portion of the panel blank over the side edge of the first tool, with the outer surface layer extending over substantially all of the structural layer within the edge portion.
  • the method for forming the panel may include forming a three-dimensional surface contour on the main portion of the panel blank by compressing the panel blank between an mold surface on the first tool and a mold surface on the second tool.
  • the method may further include selecting a particular perimeter die blade that is capable of drawing the edge portion of the panel blank around the edge of the first tool, and also cut the panel blank at the location where the panel blank engages the cutting surface of the first tool.
  • the present invention provides a cost effective, aesthetically pleasing panel for use in office furniture or a variety of alternative applications.
  • the visible outer layer may be an aesthetically pleasing material, while the structural layer provides the necessary structural characteristics.
  • the panel may be formed in a single molding step that creates both a three-dimensional surface on the main portion of the panel, as well as a finished edge portion.
  • Fig. 1 is a perspective view of a three dimensional panel according to one embodiment of the present invention.
  • Fig. 2 is a front view of three layers of material according to one embodiment.
  • Fig. 3 is a top perspective view of a corner of the three dimensional panel.
  • Fig. 4 is a bottom perspective view of a corner of the three dimensional panel.
  • FIG. 5 is a front view of the upper and lower tools in a spaced apart position with a heated panel blank in between according to one embodiment of the present invention.
  • Fig. 6 is a cross sectional view of a three dimensional panel formed in a tool according to one embodiment.
  • Fig. 7 is perspective view of five layers of material according to a second embodiment of the present invention.
  • Fig. 8 is a front perspective view of a three dimensional panel according to another embodiment of the present invention.
  • FIG. 9 is a front perspective view of a three dimensional panel according to another embodiment of the present invention.
  • Fig. 10 is a perspective view of a three dimensional panel according to another embodiment of the present invention.
  • Fig. 11 is a perspective view of a three dimensional panel according to another embodiment of the present invention.
  • a three dimensional panel 10 and a system and method for making a three dimensional panel are shown in the Figures.
  • the panel 10 generally includes an outer surface, an inner surface and a wrapped, finished outer edge.
  • the apparatus for making the panel generally includes at least one mold having a surface that is shaped to form the panel to a desired three dimensional surface, and a die blade that is sized to cut the perimeter of the panel to a desired size. As the panel blank is pressed in the tool, the mold forms the desired surface in the panel 10 and the die blade pulls the edges of the blank downwardly to form the finished edge on the panel 10.
  • the panel 10 is formed from a plurality of layers. As illustrated in Figs. 1 and 2, in one embodiment, the panel 10 is formed from a first layer, known as the "A" layer, a second layer, known as the "B" layer and a third layer, known as the "C” layer.
  • the first layer forms the visible outer surface of the panel, and may be formed from a variety of materials, such as polyester, polyethylene or another plastic fiber, or a paper based scrim that may be a mixture of wood pulp and polyester fiber, or another natural fiber.
  • the first layer may have a variety textures that are desirable for the visible, finished outer surface, and it may be colored with a desired color.
  • the A layer is opaque, such that the other layers cannot be seen through the A layer in the finished product.
  • the C layer is typically a structural layer that is capable of being molded into a desired shape. As shown, the C layer is a non-woven polyester mat. In one embodiment, it may be formed from a non-woven mat of 20 oz./yd 2 polyethylene terephthalate (PET) having a 25/75 blend (25% matrix fiber + 75% low melt bico/binder fiber). In one embodiment, the material used for the structural layer has a binder activation temperature that is greater than 200 degrees F. Alternatively, the structural layer may be formed from another non- woven polymeric mat, or a blend of polymeric and natural fibers, or from another moldable material.
  • PET polyethylene terephthalate
  • the B layer is an adhesive layer that binds the A layer and the C layer together. It may be a heat activated adhesive.
  • the particular adhesive material used for the adhesive layer is dependent on the materials used for the A and C layers, as the adhesive must be capable of bonding the A layer to the C layer.
  • Conventional adhesives that may be used include: 50 g/yd 2 Bostik PE75, 14 g/yd 2 Spunfab PA-1541-050, and Spunfab D0213S-060, although a wide variety of other known adhesive layers or webs may be used.
  • the panel may include more than three layers.
  • the panel may include five layers.
  • the panel includes the A, B and C layers as described above, and it additionally includes a D layer that is a second adhesive layer positioned next to the C layer on the opposite side as the B layer, and an E layer that forms a visible lower surface.
  • the E layer may be formed from the same types of materials as the A layer, or it may be formed of a structural layer that adds a degree of stiffness to the panel. Additional layers of adhesives and additional structural layers may be added to adjust the thickness and structure of the panel as desired.
  • the panel may be comprised of a single structural layer, for instance, a structural layer that has a desired color such that the outer layer of the structural layer will be the visible layer of the final panel.
  • FIGs. 1, 3-4, and 8-11 show views of various molded three dimensional panels. More particularly, Fig. 1 shows a molded panel according to one embodiment, wherein the panel 10 includes a plurality of concave, circular indentations 20. Figs. 3 and 4 show close-up views of the finished edge 22, which can be included in any of the panel embodiments. Fig. 3 shows a top partial view, including the indentations 20 formed during the molding process. Fig. 4 shows a bottom partial view of the panel 10, including the convex protrusions 21 that form the rear surface of the indentations 20. [0027] As shown in Figs.
  • the panel 10 generally includes an upper surface 13 formed primarily of the A layer, a lower surface 15 opposite the upper surface 13 and formed primarily of the C layer, and an edge portion 22.
  • the edge portion 22 of the panel extends downwardly from generally horizontal main portion 23 at the periphery of the panel 10. As shown, the edge portion 22 includes an interior surface 27 formed by the edge portion 28 of the C layer and an exterior surface 29 formed by the edge portion 26 of the A layer.
  • the edge portion 22 of the panel 10 has a finished appearance due to the edge portion 26 of the A layer being wrapped around substantially the entire edge portion 28 of the C layer. This results from the edge portions 26, 28 of both the A and C layers being pulled downwardly during the die cut process described below, with the edge of the A layer being pulled over the edge of the C layer.
  • the A layer extends over substantially all of the C layer, such that only a small portion of the terminal edge 24 of the C layer is visible from the side of the panel 10.
  • the finished edge portion 22 may extend around the entire panel 10, including the corners 30, or, alternatively, the finished edge may extend around predetermined portions of the panel 10.
  • the edge of the A layer is pulled completely over the edge of the C layer, such that no portion of the C layer is visible from the side of the panel.
  • Figs. 8-11 show various alternative embodiments of the panel, which are substantially the same as the embodiment shown in Figs. 1-4, except that they are provided with alternative surface contour patterns by using molds with different mold surfaces.
  • Fig. 8 shows a molded panel 12 according to one embodiment, wherein the panel 12 includes a plurality of convex, circular projections 14 extending outwardly from the generally planar front surface 13 of the panel 12.
  • Fig. 9 shows an embodiment of a panel 40 including a plurality of evenly spaced, generally square protrusions 42 in the front surface 44 of the panel 40.
  • FIG. 10 shows an embodiment of a panel 50 including a plurality of serpentine-shaped protrusions 52 that are generally evenly spaced apart across the front surface 54 of the panel 50.
  • Fig. 11 shows an embodiment of a panel 60 including a plurality of generally rectangular shaped indentations 62 that are generally evenly spaced apart across the front surface 64 of the panel 60.
  • Figs. 5-6 show one embodiment of the tooling that may be used to form the panels.
  • the tooling includes an upper tool 90 and a lower tool 100 that can be pressed together about a pre-heated panel blank 11 of the layered materials, for instance, with hydraulic arms attached to one or both of the tools or another conventional method.
  • the lower tool 100 includes a base 102 that may be mounted to a support structure (not shown).
  • the base 102 is formed from plywood or aluminum, but a variety of materials can be used.
  • the base 102 includes an upper surface 106, with an approximately 1" tall, 4 point blunt rule die 110 mounted thereto.
  • the die 110 may be mounted to the support structure (not shown) and extend upwardly through an opening in the base 102.
  • the die 110 generally extends upwardly from the base 102 to form a perimeter side edge for the lower mold 114.
  • the die blade 110 forms a generally square perimeter, which is approximately the desired size of the perimeter of the finished three dimensional panel 10.
  • the perimeter shape may be varied from application to application, depending on the desired shape of the panel 10.
  • the lower mold 114 is fitted within the perimeter formed by the lower die 110.
  • the lower mold 114 made be formed form a variety of materials, such as aluminum, polycarbonate, REN or masonite.
  • the lower mold 114 is aluminum.
  • the lower mold 114 generally includes an upper surface 118 and a bottom surface 120.
  • the upper surface 118 may be provided with a predetermined contour for forming the panel blank into a desired shape. As shown, the upper surface 118 includes a plurality of circular, concave indentations, or dimples, 122 defined therein.
  • the dimples 122 are spaced slightly apart from each other and aligned in rows along the upper surface 118, with partial dimples 122 located near the perimeter of the lower mold 114.
  • the upper surface 118 may be provided with a variety of other contours, in order to form panels with different surface patterns and shapes (such as the panels shown in Figs. 8-11).
  • the bottom surface 120 of the lower form 114 is mounted to a masonite filler 124 that is mounted to the base 102, for instance, by conventional fasteners or a conventional adhesive.
  • the bottom surface 120 may be mounted directly to the base 102.
  • the bottom surface 120 may be generally flat, or, as illustrated in Fig.
  • a cutting plate 130 may be attached to the upper surface 106 of the base 102 around the outside of the perimeter die 110.
  • the cutting plate 130 is designed to receive impact from a blade 36 on the upper tool (discussed below), and, in one embodiment, is removably attached to the base 102, for instance, with a plurality of fasteners (not shown), such that the cutting plate 130 can be replaced after it is worn out.
  • the cutting plate 130 is formed from nylon or aluminum, or from another material that is capable of outlasting high density polyethylene, and, preferably, a material that is capable of outlasting high density polyethylene 10:1.
  • Figs. 5 and 6 also show an embodiment of the upper tool 90, spaced above the lower tool 100 and directed downwardly so it is capable of forming the blank 11 between the upper 90 and lower 100 tools.
  • the upper tool 90 includes a top base 92 that is generally similar to the base 102 of the lower tool 100.
  • the top base 92 is a generally flat support plate that includes an upper surface 142 and a lower surface 144.
  • the top base may be formed from a variety of materials, such as aluminum or plywood.
  • the upper surface 142 is mounted to a support structure (not shown), which may include a hydraulic arm (not shown) or other apparatus for raising and lowering the upper tool 90.
  • the upper tool 90 includes an upper mold 146 and a perimeter die blade 36.
  • the upper mold 146 includes an upper surface 148 and a lower surface 105.
  • the upper surface 146 is mounted to a filler 34, that is made from masonite, or another generally hard material, and mounted to the top base 92.
  • the lower surface 105 may have a three-dimensional shaped contour pattern, and, in the embodiment shown in Figs. 5-6, it includes a plurality of dome-shaped protrusions 160 that align with the dimples 122 on the lower mold 114.
  • the upper form may be made from a variety of materials, such as aluminum, polycarbonate, REN or masonite.
  • the perimeter blade 36 extends around the perimeter of the upper form 146, and is sized to cut the perimeter of the panel blank 11 to form a finished panel 10 with the desired exterior dimensions.
  • the blade 36 extends in a generally square shape that is slightly larger than the perimeter of the lower form 114 formed by the lower die 110. This forms a gap between the blade 38 and the die 110 when the tools are closed together that has approximately the desired thickness of the finished panel edge 22.
  • the blade 36 may be particularly selected to aid in forming the finished edge 22 on the panel 10. More particularly, the size, shape and sharpness of the blade 36 may be specifically selected in order to provide a blade 36 that is capable of pulling the edge portion 22 of the panel blank 11 over the edge of the lower die 110.
  • the tip 38 is a 4-point, steel ruled, center beveled die blade; however, some panel materials may be cut more easily than others, and may require a duller tipped blade, and some panel materials may be tougher to cut than others, and may require a sharper die blade.
  • the blade 36 includes a base 37 that extends through a notch in the top base 92 and is mounted to the support structure (not shown). Alternatively, the blade 36 may be mounted directly to the base 92 or other support structure.
  • the tip 38 of the blade 36 extends beyond the lower surface 105 of the upper mold 146, in order to create the desired depth of the edge portion 22 of the panel 10. In the illustrated embodiment, the tip 38 of the blade 36 extends about 0.375" beyond the lower surface 105 of the upper form 146.
  • the upper tool 90 may additionally include an exterior foam section 32, or sections 32.
  • the exterior foam 32 provides pressure to the perimeter edge of the blank 11 as the edge is pulled by the tip 38 of the blade 36 over the edge of the lower tool 100 to prevent wrinkling and other blemishes on the edge of the panel 10.
  • the outer foam 32 may be flush against the outer surface of the blade, and it may extend around the entire blade or portions thereof.
  • the foam 32 may additionally protect the tooling operator from contacting the cutting edge 38.
  • the foam 32 may be made of any type of compressible material, including foam, such as polyurethane.
  • manufacture of a panel 10 includes placing the blank 11 - including a desired number of layers arranged appropriately on top of each other - into a conventional oven and heating the oven to a temperature that is above the melting temperature of the structural layer, and above the temperature necessary to activate the adhesive, if any.
  • the heated blank 11 is then placed on top of the lower tool 100, with the A layer facing the upper tool 90.
  • the upper tool 90 is then lowered (or the lower tool raised) to compress the heated blank 11 between the upper 90 and lower 100 tools.
  • the heated blank 11 is pressed between the upper form 146 and the lower form 114, and molded into the shape of the contoured surfaces of the upper 146 and lower 114 forms.
  • the protrusions 160 on the upper form 146 align with the dimples 122 on the lower form 114 to compress the blank 11, forming the spaced apart, concave, circular dimples 20 in the finished panel 10.
  • the edge portion of the blank 11 - which will form the edge portion 22 of the finished panel 10 - is pulled around the edge of the die 110 of the lower tool 100 by the tip 38 of the die blade 36, forming a downwardly extending edge portion 22 on the finished panel 10.
  • the edge of the A layer is pulled down over substantially all of the edge of the structural C layer to form an aesthetically pleasing finished edge 22.
  • the edge of the structural layer is pulled downward to have a finished appearance.
  • the die blade 36 may extend downwardly until the tip 38 engages the surface of the cutting plate 130, cutting the terminal edge 24 of the panel 10 as the panel 10 is pinched between the blade tip 38 and the cutting plate 130.
  • the tools 90, 100 may then be moved apart from each other, and the finished panel 10 removed and cooled, such that it hardens in its formed state.
  • top 146 and bottom 114 molds are shown in the illustrated embodiment, other embodiments may include only a top or bottom form for shaping only one surface of the panel 10. Further, in one embodiment, the tool may not include a mold surface, and may simply be used to form flat panels with finished edges.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Textile Engineering (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

L'invention porte sur un panneau, tel qu'un panneau de bureau, qui comprend un bord périphérique fini intégré. Dans un mode de réalisation, le panneau comprend une couche structurelle et une couche de surface externe visible. La couche structurelle peut être moulée de telle sorte que sa surface supérieure ait un motif de contour de surface en trois dimensions. La couche externe visible est fixée à la surface supérieure, et suit le motif de contour de surface de la couche structurelle. Les parties de bord des deux couches sont tirées autour du bord latéral d'un outil durant le processus de moulage, de telle sorte que le bord de la couche externe couvre sensiblement toute la partie de bord de ladite couche structurelle, de façon à former un bord fini intégré sur le panneau.
PCT/US2009/044927 2008-06-03 2009-05-22 Panneau de bureau Ceased WO2009148851A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US5834508P 2008-06-03 2008-06-03
US61/058,345 2008-06-03

Publications (1)

Publication Number Publication Date
WO2009148851A1 true WO2009148851A1 (fr) 2009-12-10

Family

ID=41398441

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2009/044927 Ceased WO2009148851A1 (fr) 2008-06-03 2009-05-22 Panneau de bureau

Country Status (1)

Country Link
WO (1) WO2009148851A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2504262A (en) * 2012-06-01 2014-01-29 Peter Vautier Cladding with depressions for deflecting urine

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040028958A1 (en) * 2002-06-18 2004-02-12 Total Innovative Manufacturing Llc Recyclable fire-resistant moldable batt and panels formed therefrom
US20080098685A1 (en) * 2006-10-25 2008-05-01 Polk Dale E Molded panel and panel assembly

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040028958A1 (en) * 2002-06-18 2004-02-12 Total Innovative Manufacturing Llc Recyclable fire-resistant moldable batt and panels formed therefrom
US20080098685A1 (en) * 2006-10-25 2008-05-01 Polk Dale E Molded panel and panel assembly

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2504262A (en) * 2012-06-01 2014-01-29 Peter Vautier Cladding with depressions for deflecting urine

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