EP3079908A1

EP3079908A1 - Process for manufacturing a honeycomb structured panel and product obtained therefrom

Info

Publication number: EP3079908A1
Application number: EP14828506.7A
Authority: EP
Inventors: Franco Paulon
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-12-09
Filing date: 2014-12-04
Publication date: 2016-10-19
Also published as: ITPN20130072A1; WO2015087150A1

Abstract

A process for manufacturing a honeycomb structured panel and a so obtained honeycomb structured panel is described. The honeycomb structured panel (8) is composed of a first central body (9) and an external body (10), applied on to the entire longitudinal and transversal surface of the central body (9), and formed by two flat component elements (11, 12) having equal surface, overlapped and joined to each other, of which the first central component element (11) is formed by at least a flat layer of wooden material such as for example chipboard, MDF, plywood or the like, and the second covering component element (12) is constituted by at least a flat layer having the width equal to the previous component element (11), which may be obtained with different foldable materials such as for example paper, leather, wood, metal etc.. with protective film.

Description

"PROCESS FOR MANUFACTURING A HONEYCOMB STRUCTURED PANEL AND PRODUCT OBTAINED THEREFROM"

The present invention concerns a process for manufacturing a honeycomb structured panel, adapted to be used for realizing furniture and furnishings components of various kind.

The invention also relates to a honeycomb structured panel obtained with the above mentioned manufacturing process.

At the present time, the doors and the wings for wardrobes and furniture and furnishing components in general are advantageously made by utilizing large quantities of honeycomb structured panels, which have a very low specific weight, which makes lighter these products ; should these wardrobes, furniture and components be made with simple chipboard panels or medium density (MDF) panels, which have a very higher specific weight, they would be very heavier.

The honeycomb structured panel is also used frequently for panels with large thickness, for realizing flanks for wardrobes, shelves, planes for living-rooms and any application requiring a light weight, not to be deformable and sturdiness associated with considerable thicknesses for the technicians of the field. This honeycomb structured panel guarantees an increase of the strength and the stability of the single elements and consequently of the entire realized structure and a longer duration of the screw anchoring junctions, even after repeated assembling operations.

At the present time, a process for manufacturing a honeycomb structured panel is known, adapted to be employed for assembling furniture and having characteristics of lightness and mechanical resistance, which foresees the construction of a peripheral frame of wood, or constituted by chipboard or medium density (MDF) materials.

In un subsequent step, in the fully empty zone being created in the interior of such frame, it is introduced a honeycomb made structure, then in a subsequent operative step and in the upper part and lower part of said frame it is applied a respective covering panel always made of chipboard, medium density (MDF) material or plywood, thereby closing the so obtained honeycomb structured panel. Such honeycomb made structure may be constituted by an alveolar structured paper or, for increasing additionally the resistance and the structural characteristics of the panel, the structure may be constructed with ingots of foamed

polyurethane or polystyrene or with plastic or aluminium made honeycomb. Finally, the so obtained honeycomb structured panel is squared and flanged on the four sides thereof at the final sizes of the furniture component to be realized, with the edge of the same colour of the surface. The so obtained honeycomb structured panel is normally ennobled and machined like a normal chipboard panel, with the application of veneerings, laminates, polymeric or melaminic sheets. Such process has some drawbacks, among others the fact that the panels which may be produced therewith have limited dimensions, in that owing to the fact that the peripheral frame must be necessarily constructed with pre-selected sizes, during the design phase it must be considered in advance that the cuttings, the hardware, the hinges and the screws may be applied on to the panel frame only and not on to the honeycomb structured central part thereof.

Often, for this ground at the industrial level the cuttings effected at measure of wings and doors are more complex with this type of material.

A second process of known type consists of glueing two layers, usually made of chipboard, medium density (MDF) material or plywood having dimensions identical to those ones of the chipboard panels in commerce, in the interior of which an alveolar structure with very small alveolus of rigid type is inserted. The so obtained panel is cutaway at the final sizes of the furniture component to be realized, and is flanged at a considerable extent, in that the wood strip isn't provided, in accordance to the same previously described process. In this case, the screws need some expanding bushes.

A drawback of the above mentioned known manufacturing technologies of a honeycomb structured panel consists of the need to square and flange the panels, which steps are effected by employing different types of machineries and which involve long and expensive working times, and the production of a lot of scraps of the utilized materials, both in the squaring and the trimming step.

Another drawback of such known processes consists in that the global aesthetical appearance of the honeycomb structure panel is getting worse by the presence of the flanging, namely of the line interrupting two subsequent edges, which is clearly visible in correspondence of each edge joining two sides, so that for obtaining a honeycomb structured panel with an agreeable and not discontinuous appearance, along the peripheral surface thereof it is needed to perform a possible lacquering step, which is also expensive in term of working time and costs.

Finally, it can be noticed that such described processes are performed with many operative steps, requiring different machineries and a very complex working and co-ordinated organization, which is difficult to be achieved by some artisans and small firms which aren't provided with the needed equipment and the organized know-how.

The object of the present invention is to eliminate the above mentioned drawbacks, by means of a manufacturing process allowing to produce honeycomb structured panels in a simple, quick and continuous manner, adapted to realize a continuous peripheral surface, by eliminating in particular the flanging step, and therefore by reducing the manufacturing times, and with considerably reduced production costs.

This manufacturing process of a honeycomb structured panel and the so obtained honeycomb structured panel are effected with the substantially described structural characteristics, with particular reference to the enclosed patent claims and the accompanying Figures :

- Figure 1 showing a perspective front view of a honeycomb structured panel in accordance to the invention ;

- Figure 2 showing a perspective side view of a first step of the production cycle of the honeycomb structured panel of the invention ;

- Figures 3 a - 3 c showing a perspective front view of a second step of the production cycle, in three different embodiments thereof ;

- Figure 4 showing a perspective front view of a third step of the production cycle ;

- Figures 5 a - 5 c showing a perspective front view of a further step of the production cycle, in three different embodiments thereof ;

- Figures 6 a - 6 b showing a perspective front view of still another step of the production cycle, in two different embodiments thereof ;

- Figure 7 showing a perspective front view of the last step of the production cycle.

The present invention relates to a process for manufacturing a honeycomb structured panel and a honeycomb structured panel for realizing doors, wings for wardrobes and furniture and furnishing components of various kind, shelves sides, planes for living-rooms or panels of large thickness and any other product requiring lightness, not to be deformable and sturdiness associated with considerable thicknesses for technicians skilled in the field. Referring to the Fig. 1 , in which a honeycomb structured panel 8 according to the invention is shown, which is obtained with the process which will be described later on, and in the example shaped of parallelepiped form, it is noted that it is composed of a first central body 9, formed by at least a layer made of lightweight material with flat peripheral surfaces, of which some examples of such lightweight material will be indicated later on, and on to such layer it is applied, onto all the longitudinal and transversal surface thereof, a second external body 10 formed by two flat component elements 1 1 and 12, with equal surface, which are overlapped and joined to each other, some examples of the materials constituting the same component elements will be described later on. Referring to the Fig. 2, in which a first step of the production cycle of the honeycomb structured panel of the Fig. 1 is shown, it can be noted that on to the first central component element 11, formed by a flat parallelepiped layer made of wooden material such as for example chipboard, medium density (MDF) material, plywood or the like, the second covering component element 12 is applied, which is constituted by a flat parallelepiped layer having a width equal than that of the previous component element 11 , which may be obtained with different foldable materials such as for example paper, leather, wood, metal, etc., with protective film, which initially is rolled on itself

for forming a reel 13 and thereafter is unrolled gradually so as to form a sheet of material 14, which is applied and secured perfectly with adhesives onto all the external surface of the first component element 11, thereby forming the single external body 10, and thereafter, when the application is completed with the desired size, the remaining part of the second component element 12 if the reel 13 is cut, in such a way that such component element 12 may be used for forming additional panels in the same manner. With reference to the Figs. 3 a- 3 c, showing a second step of the production cycle, in three different embodiments thereof, it is noted that on to the external surface of the first component element 11 there are provided for a determinate depth some rectilinear engravings 15, by means of milling, in the transversal direction and for all the length of the same external surface, and such engravings 15 may be for example at a right angle 16, namely V-shaped (see Fig. 3 a), with bevelled angle 17 (see Fig. 3 b), or at right angle with bevelled edge 18 (see Fig. 3 c), and of course they can have also other forms, in order to allow to bend the component element 11 along all the extension of the various engravings, for the ground which will be described.

Such engravings 15 are spaced away transversally to each other in a way to define the correspondent external edges of the external body 10, which will be folded later along all the different engravings 15, so as to adapt the same entire external body on to the first central body 9 as it will be described later on. In particular, in the example of the Fig. 4, it can be noted that two engravings 15 are provided parallel to each other in the respective side positions of the body 10, by defining two short side strips 19 and 20 with the same width and delimited by a relative side edge 21 and 22, which are shaped for being able to be coupled to each other, while two additional engravings 15 are provided, parallel to each other and with respect to the previous engravings, in the central area of the external body 10, and they are spaced away to each other of a distance equal to the widths of both said side strips 19 and 20, and each one of these engravings is spaced away from the opposite engraving of the same area of surface 23, for being able then to house and to wrap the central body 9 with the external body 10. With reference to the figs. 5 a - 5 c, shown therein is

the subsequent step of the production cycle, in three different embodiments thereof, in each one of which it is noted that the lower larger surface 24 of such central body 9 is laid on and fixed with an adhesive on to one of the surfaces of the first component element 11, in the Figures constituted by the right surface, in a manner that the vertical side edges 25 and 26 of such central body 9 be arranged in correspondence of the relative engravings 15, wherein the left side edge 25 be located near the surface portion 27 delimited by the engravings of the central area of the external body, while the right side edge 26 be located near the side strip 20, the width of which is preferably the half of the height of the same side edge. The central body 9 is formed by a layer made of lightweight material, in the first embodiment (Fig. 5 a) for example of polystyrene, in the second embodiment (Fig. 5 b) for example of foamed pol urethane, and in the third embodiment (Fig. 5 c) by a honeycomb layer made of paper, plastic or aluminium, preferably with rigid and small alveolus. Later on, as visible in the Figs. 6 a and 6 b, the external body 10 is folded on itself for its entire length, in correspondence of the remaining engravings 15, in such a way that it encloses completely and perfectly the central body 9, and that such remaining engravings 15 arrange themselves in a position correspondent to the edges to the central body 9 through appropriate adhesive distributed in advance. In the Fig. 6 a, in particular, in which the central body 9 has the same shape and size of that one of the Figs. 5 A, 5 B and 5 C, it is noted that the external body 10 is bent at first along the two engravings 15 of the left side of the same body, in a mariner that the surface portion 27 delimited by such engravings be arranged adherent to the left side edge 25, and that the other left side surface 29 of the first component element 11 be arranged in a position overlapped on and adherent to the upper larger surface 30 of the central body 9.

Then, under this condition, as visible in the Fig. 7, the side strip 19 of the external body 10 is bent orthogonally downward along the relative engraving 15, while in turn the other side strip 20 too of the external body 10 is bent orthogonally upward, until the relative side edges 21^" and 22 of such

strips 19 and 20 are put at first into contact to each other and then are coupled opportunely, i.e. through fixed joint etc... by letting themselves to adhere perfectly to the correspondent right side vertical side edge 26 of the central body 9, thereby defining the other surface portion opposed to the preceding portion 27, wherein the joining area of the two side strips 19 and 20 doesn't appear visible and so confers a continuous aesthetical appearance even to this surface portion of the so formed honeycomb structured panel.

In the Fig. 6 B it is noted that the central body 9 is realized with five sides instead of four sides as in the case of the Fig. 6 A, and also the external body 10 is shaped with five sides correspondent to those ones of the central body 9, and in the same external body there are provided additional engravings 15 in correspondence of the different edges of these sides of the central body 9, and the external body 10 is applied on to the central body 9 in a manner identical to the above described manner. Obviously, with the same operative steps there may be covered even central bodies 9 having different numbers of sides and shaped in a different manner too, for obtaining the honeycomb structured panels, thus without departing from the protection field of the present invention. A soon as such steps are terminated, it is effected a last pressing operative step, not shown, in which by using conventional equipment the external body 10 is pressed, along all its perimeter and for its entire length, onto the central body 9, in such a manner that it adheres perfectly thereon, thereby obtaining the honeycomb structured panel ready for being delivered.

The honeycomb structured panel made with this process therefore has all the above described advantages, without the drawbacks deriving from employing the present manufacturing technologies. Moreover, this process allows to realize a bar-shaped honeycomb structured panel, with sizes which can be obtained to measure and by shortening the working times of the different operative steps and therefore with less stocks of wares.

Claims

1) Process for manufacturing a honeycomb structured panel for realizing doors, wings of wardrobes and furniture and furnishing components of various kind, of shelves sides, planes for living-rooms, or panels with large thickness and any other product that requires lightness, not to be deformable and sturdiness associated with considerable thicknesses for the technicians of the field, the honeycomb structured panel (8) being composed of a first central body (9), formed by at least a layer made of lightweight material such as for example the polystyrene, the foamed polyurethane, a honeycomb layer made of paper, plastic material or aluminium, etc., and also formed by a second external body (10) applied onto all the longitudinal and transversal surface of said layer of lightweight material, characterized by the following operative steps :

a) application and fixing of said second external body (10) onto all the peripheral surface and for all the length of said central body (9), wherein said external body (10) is formed by at least two flat component elements (11, 12), with equal surface, overlapped and joined to each other, of which said first central component element (1 1 ) is formed by at least a flat layer made of wooden material such as for example chipboard, MDF, plywood or the like, and said second covering component element (12) is constituted by at least a flat layer with a width equal than that of the previous component element (11), which may be made with different foldable materials i.e. paper, leather, wood, metal, etc., with protective film, said second component element (12) being initially rolled on itself for forming a reel (13) and thereafter being unrolled gradually so as to form a sheet of material (14), which is applied and secured perfectly with adhesives onto all the external surface of said first component element (11), thereby forming the single external body (10), and thereafter, when the application is completed with the desired size, the remaining part of the second component element (12) of the reel (13) is cut, in such a way that such component element (12) may be used for forming additional panels in the same manner ;

b) providing a set a rectilinear engravings (15) for a determined depth onto the external surface of said first component element (1 1), in the transversal direction and for all the length of the same external surface, which engravings (15) may be shaped with different shapes, for example at a right angle (16), namely V-shaped, with bevelled angle ( 17), or at right angle with bevelled edge (18), and naturally they can have also other shapes, in order to allow to bend said component element (1 1) along all the extension of the various engravings (15), said engravings (1 ) being spaced away transversally to each other in a way to define the correspondent external edges of the external body (10), which will be folded later along all the engravings (1 ) which are provided, so as to adapt the same entire external body on to the first central body (9), said engravings (15) being provided on to the external body (10) in a manner to define at least two short side strips (19, 20) with the same width and delimited by a relative side edge (21, 22), which are shaped for being able to be coupled to each other, and additional engravings (15) being provided in the central area of the external body (10), and spaced away to each other of a distance equal to the widths of both said side strips (19, 20), and these additional engravings being spaced away to each other in a manner to be able then to house and to wrap said central body (9) with said external body (10) ;

c) arrangement of the lower larger surface (24) of said central body (9) onto one of the surfaces of said first component element (1 1), and fixing the same in position, in a manner that the vertical side edges (25, 26) of such central body (9) be arranged in correspondence of the relative engravings (15), and that one of the side edges (25) be located near the surface portion (27) delimited by the engravings of the central area of the external body, and is let to adhere to such surface portion (27), while the other one of the side edges (26) be located near the side strip (20), the width of which is preferably the half of the height of the same side edge ;

d) folding of said external body ( 10) on itself for its entire length, in correspondence of the additional engravings (15), in such a way that it encloses completely and perfectly the central body (9), and that such additional engravings (15) be arranged in a position correspondent to the edges (28) of the same central body, and fixing of said external body (10) irremovably in this position

overlapped to the central body (9), preferably through appropriate adhesive distributed in advance ;

e) bending said side strip (19) downward along the relative engraving (15), and bending the other side strip (20) too upward along the relative engraving (15), until the relative side edges (21, 22) of such strips (19, 20) are put at first into contact to each other and then are coupled opportunely, i.e. through fixed joint, etc.... by letting themselves to adhere perfectly to the correspondent side edge (26) of said central body (9), thereby defining the other surface portion opposed to the previous portion (27), wherein the joining area of the two side strips (19, 20) doesn't appear visible and so confers a continuous aesthetical appearance even to this surface portion of the honeycomb structured panel ;

f) pressing said external body (10) onto said central body (9) along all its perimeter and for its entire length, in a manner to obtain a perfect adhesion, so as to achieve the honeycomb structured panel ready for being delivered.

2) Honeycomb structured panel obtained according to the manufacturing process of the claim 1, characterized in that to be composed of said first central body (9) and said external body (10), applied onto all the longitudinal and transversal surface of said central body (9) and formed by at least two flat component elements (11, 12), with the same surface, overlapped and joined to each other, of which said first central component element (11) is formed by at least a flat layer of wooden material such as for example chipboard, MDF, plywood or the like, and said second covering component element (12) is constituted by at least a flat layer with width equal than that of the previous component element (11), which may be obtained with different foldable materials i.e. paper, leather, wood, metal, etc., with protective film.

3) Honeycomb structured panel according to claim 2, characterized in that said central body (9) and said external body (10) are realized with four sides and with parallelepiped shape and that said external body (10) is let to adhere with its first surface portion (27) to one of the side edges (25) of said central body (9), with its two larger surfaces (24, 29) onto correspondent larger surfaces of said central body (9), and that said external body (10) is shaped with two side strips (19, 20) that, in the overlapped position of the external body (10) onto the central body (9), are bent in opposite directions and joined to each other as well as let to adhere to the other side edge (26) of said central body (9).

4) Honeycomb structured panel according to claim 3, characterized in that said central body (9) and said external body (10) are shaped with five sides correspondent to each other and the application of the external body (10) onto the central body (9) occurs in a manner identical to that of the central body (9) and the external body (10) shaped with four sides.