FR2713133A1 - Over-moulded edging for furniture panel - Google Patents

Abstract

An over-mould edging is formed on a substrate partic. on a furnishing panel, by: preparing the panel (10) having a face (20), reverse face (22) and an edge (14) of chosen profile; placing the panel in a mould (24) to form a space (30) between panel edge and mould; running by gravity, a hardenable resin into the space to fill it and form a continuous layer in contact with the panel; allowing resin to harden then removing panel from mould. The resin is polyester based, contg. colourants, or pigment filler. The resin bead is surfaced prior to application of a final surface finish coating.

Description

Method for forming a molded edge on a substrate.

and substrate thus obtained
The invention relates to a method of forming an overmolded border on a substrate, in particular on a furniture or decoration panel, and the substrate thus obtained.

There are already known substrates of this kind which are used to constitute furnishing or decorative elements, for example for making worktops, table tops, side panels, etc.

The substrate can be formed from a solid material, such as wood or derived materials, in particular particles or fiber-based materials, plywood, etc.

The substrate can also be formed of a composite element, for example of a structure of the honeycomb type, or also of a rigid foam.

In the aforementioned applications, the substrate usually comprises a face and a backing, most often flat and parallel to each other, as well as a song also called "edge" or "edge" which is located at the junction of the face and the counterface.

Such substrates generally receive a coating which is applied to the face and, if necessary, another coating applied to the backing.

It can be a bonded covering such as, for example, a decorative plate, a laminate, a plating material, a woven covering, etc.

Alternatively, it may be a coating applied by coating, such as a lacquer or a paint.

Generally, such a substrate also receives an edge which has in particular the function of ensuring the protection of the edge of the substrate with respect to impacts and of ensuring the finishing of the substrate by ensuring continuity with the coating applied to the face and , if necessary, with the coating applied to the backing.

We already know different types of borders applied to the edge of a substrate.

It is known, for example, to produce a border in the form of a profile, usually made of plastic, which comprises a decorative part forming the border proper and an anchoring part capable of being inserted into a groove made beforehand in the edge of the substrate.

In addition to the fact that the installation of such a border requires the installation of a groove in the substrate, it should be noted that it does not make it possible to obtain a perfect finish since there necessarily exists a junction zone. between the two ends of the profile and that dirt tends to lodge at the junction of the profiled edge and of the coating or coatings of the substrate.

Edges are also known which are intended to provide localized protection on the edge of a panel, in particular of a desk or table top, only at the corners of the top. These are either added metal elements, for example aluminum, or polyurethane elements, molded only at the corners of the plate.

The establishment of such a molded edge is therefore carried out only in the region of the angles of the plate. In addition, it requires a special arrangement of the angles of the plate and its installation is carried out only on a substrate already provided with a coating. This also results in the possibility that soiling becomes lodged at the junction of the overmolded edge and of the coating or coatings of the substrate.

Other types of overmolded edges have also been proposed which require the arrangement of particular attachment profiles at the edge of the substrate, and the positioning of which is carried out on the already coated substrate.

 I1 also results in the disadvantage that soiling can come to lodge at the junction of the edge and of the coating or coatings of the substrate.

Another drawback of known overmolded edges is that their formation process requires a large number of long and costly operations which, moreover, are only suitable for substrates of well-defined shapes.

The object of the invention is in particular to overcome the aforementioned drawbacks.

It is in particular an object of the invention to provide a process for forming an overmolded edge which can be implemented, with great flexibility of use, on a wide variety of substrates of different shapes and structures.

It is another object of the invention to provide such a method which can be implemented under rapid and economical conditions.

It is also an object of the invention to provide such a method which makes it possible to form a molded edge which is particularly impact resistant and offers a high degree of finish.

To this end, the invention provides a method of forming an overmolded border on a substrate, in particular on a furniture panel, which comprises the following operations: a) preparing a substrate comprising a face and a backing, as well as a edge having a contour and a profile of selected shapes; b) placing the substrate in a mold so as to provide a casting interval between the mold and the edge of the substrate; c) pouring by gravity a curable resin in the casting interval so as to fill this interval with resin and to form a continuous layer of resin in contact with the edge of the substrate; d) allow the resin to harden; and e) removing the substrate whose edge comprises the hardened resin layer.

Thus, the formation of the border essentially comprises the application of a curable resin on the edge of the substrate, by gravity casting of the resin in a mold.

According to another characteristic of the invention, the preparation operation a) comprises cutting the substrate to form a contour whose shape corresponds at least approximately to the chosen shape of the edge of the edge, as well as the profiling of the edge to give it the chosen profile.

For the implementation of operation b), the method advantageously comprises the preparation of a mold having a horizontal bottom suitable for receiving the face or the back face of the substrate, as well as a bank suitable for conforming to the outline of the edge of the substrate and to define the casting interval between the edge of the mold and the edge of the substrate.

For operation c), different types of curable resins can be used, for example resins based on polyesters, polyurethanes, or acrylic materials.

In the context of the invention, resins based on polyesters are very particularly preferred.

Whatever type of resin is used, it preferably comprises at least one dye and / or a pigmentation filler to give the border a particular decorative effect.

After operation e), the process of the invention advantageously comprises a surfacing operation f) consisting of surfacing the face and the back face of the substrate, including the lateral edges of the hardened resin layer. This gives not only a perfectly surfaced face and counterface, but also a border, the lateral edges of which are perfectly surfaced, which gives it a well-defined width.

Advantageously, the method of the invention comprises a finishing operation g) consisting in applying a coating on the face of the substrate, and if necessary another coating on the backing, so that this coating covers the edge of the layer. hardened resin.

A profiling operation h) can also be provided to give a profile of selected shape to the hardened resin layer. This profiling operation is advantageously carried out after the finishing operation g) but, as a variant, could be carried out directly after operation e) or operation f).

This profiling operation f) can be followed, if necessary, by a finishing operation i) consisting in polishing or sanding the profiled edge resulting from the profiling operation.

In another aspect, the invention relates to a substrate, in particular a furniture panel, comprising a molded edge obtained by the implementation of the method defined above.

In the description which follows, given solely by way of example, reference is made to the appended drawings, in which - FIG. 1 is a perspective view of a substrate which has just been cut from a large panel. ; - Figure 2 is a perspective view of the substrate after preparation of the outline and the profile of its edge; - Figure 3 is a partial cross-sectional view of the substrate of Figure 2; - Figure 4 shows the placement of the substrate of Figure 2 in a casting mold; - Figure 5 is a cross-sectional view of the mold and the substrate before casting the curable resin; - Figure 6 is a view similar to that of Figure 5, after casting the curable resin; - Figure 7 shows the substrate undergoing a surfacing operation of its face and its face; - Figure 8 shows the establishment of a coating on the face of the substrate; - Figure 9 is a partial cross-sectional view of the substrate after profiling the edge; and - Figure 10 shows a detail of Figure 9, on an enlarged scale.

First of all, reference is made to FIG. 1 which represents a substrate 10, in the example of rectangular outline, which has just been cut from a large panel 12. In the example, this panel is made of wood or a wood-based material.

After cutting, the substrate 10 is shaped to form a edge 14 which extends over the entire perimeter of the substrate and which is formed from four rectilinear sides 16 joined in pairs by rounded corners 18.

As can be seen in FIG. 3, the panel 10 comprises a face 20 and a counterface 22 which are plane and parallel to one another.

The edge 14 is also given a chosen profile which, in the example, is rectilinear and forms an angle a with respect to a line L which extends perpendicularly to the face 20 and to the large face 22.

Of course, it is also within the scope of the invention to give other shapes to the profile of the edge, and this according to the desired application.

The profiling of the substrate is carried out using a conventional profiling tool driven by a known machine of the router type, router, machining center, etc.

After the substrate has been prepared, it is placed in a mold 24 (FIG. 4) which includes a horizontal bottom 26 of a shape adapted to that of the substrate 10 and an edge 28 matching the outline of the edge 14.

In the example, the substrate 10 is intended to be placed flat in the mold 24, the face 20 being turned downwards to rest against the bottom 26 of the mold and the back face 22 being turned upwards. There is thus created a casting interval 30, of small width, between the edge 14 and the edge 28 (FIG. 5).

As can be seen in FIG. 5, the edge 28 is oblique and forms a draft angle which, in the example, corresponds substantially to the angle a above.

Then, a curable resin is poured by gravity into the mold so as to fill the casting interval 30 by forming a layer of resin 32 which completely covers the edge 14 and which projects slightly above the plane of the back surface 22 (FIG. 6).

The curable resin can be of the polyester, polyurethane, acrylic, etc. type. It is advantageously colored or charged with mineral or synthetic elements, to give it a particular decorative appearance.

In the context of the invention, it is preferred to use polyester type resins.

A polyester resin which is very particularly suitable for implementing the invention is that sold under the brand GRANULON. This resin already incorporates fillers and is released ready for use with an appropriate hardener.

This resin has been used until now for different applications with use with a spray gun. It then suffices to mix the resin and the hardener and pour them into the mold.

After hardening, the substrate 10 is removed, which takes with it the resin layer 32 which then forms an unfinished border.

To facilitate demolding, a demolding wax can be applied beforehand against the edge 28 of the mold.

Demoulding takes place after at least partial hardening of the resin, the hardening time depending on the nature of the resin, the hardening rate, the casting temperature, the volume of resin, etc.

After demoulding, the face 20 and the backing 22 are subjected to a finishing operation by means of two sanding tools 34 and 36 respectively (FIG. 7) acting in opposition.

This operation makes it possible to give a perfect and constant flatness to the face 20 and to the back face 22. It also makes it possible to surface the resin layer 32 at the same time by forming two lateral edges 38 and 40 depending respectively on the face 20 and the back surface 22. This gives a regular thickness of the substrate 10 and the resin layer 32 forming the border.

During a subsequent operation (FIG. 8), a coating 42 is applied to the face 20 and possibly another coating (not shown) on the back face 22. This coating can be applied by gluing or by coating. In the example, it is a laminated plate which is glued to the face 20. The coating 42 is applied in such a way that it projects beyond the face 20 to also cover the layer of resin 32 forming an edge.

After placement of the coating (s), the resin layer 32 is profiled by means of an appropriate tool forming part of a machine of the router, router or machining center type. This operation makes it possible to give the resin layer 32 a chosen profile such as that shown in FIG. 9.

As shown more particularly in FIG. 10, the coating 42 is profiled at the same time as the resin layer 32, and the latter covers the edge 38 of the layer 32, which makes it possible to ensure a perfect finish. This avoids any risk of fouling of dirt between the coating and the border.

The method of the invention thus makes it possible to apply, under rapid and economical conditions, and with great flexibility, borders made of synthetic resin covering the edge of a substrate, in particular of a decoration or furniture panel.

It is possible to give a chosen shape to the outline and profile of the edge, as well as to the profile of the border. This can be performed on the entire perimeter or only on a part of the perimeter of a substrate, depending on the desired applications.

It is also possible to give this border particular colors or pigmentation effects, depending on the desired application.

Claims (10)

Claims 1.- A method of forming a molded border on a substrate, in particular on a furniture panel, characterized in that it comprises the following operations a) preparing a substrate (10) comprising a face (20) and a counterface (22), as well as a song (14) having an outline and a profile of selected shapes; b) placing the substrate (10) in a mold (24) so as to provide a casting interval (30) between the mold (24) and the edge (14) of the substrate; c) pouring by gravity a curable resin into the casting interval (30) so as to fill this interval and to form a continuous layer of resin (30) in contact with the edge (14) of the substrate; d) allowing the resin layer (32) to harden; and e) removing the substrate (10) whose edge (14) comprises the hardened resin layer (32). 2.- Method according to claim 1, characterized in that the preparation operation a) comprises cutting the substrate (10) to form a contour whose shape corresponds, at least approximately, to the chosen shape of the edge of the edge ( 14), and the profiling of the edge (14) to give it a chosen profile. 3.- Method according to one of claims 1 and 2, characterized in that operation b) comprises the preparation of a mold (24) having a horizontal bottom (26) adapted to receive the face (20) or the counterface (22) of the substrate (10), and an edge (28) adapted to match the outline of the edge (14) of the substrate and to delimit the casting interval (30) between the edge (28) of the mold and the edge (14) of the substrate. 4.- Method according to one of claims 1 to 3, characterized in that the casting operation c) comprises the use of a resin comprising at least one dye and / or a pigmentation filler. 5.- Method according to one of claims 1 to 4, characterized in that the casting operation c) comprises the use of a polyester-based resin. 6.- Method according to one of claims 1 to 5, characterized in that it comprises a surfacing operation f) consisting of surfacing the face (20) and the face (22) of the substrate, including lateral edges ( 38.40) of the cured resin layer (32). 7.- Method according to claim 6, characterized in that it comprises a finishing operation g) consisting in applying a coating (42) on the face (20) of the substrate, and if necessary another coating on the back face ( 22) of the substrate, so that this coating covers the edge (38) of the hardened resin layer (32). 8.- Method according to one of claims 1 to 7, characterized in that it comprises a profiling operation h) to give a profile of selected shape to the hardened resin layer (32). 9.- Method according to claim 8, characterized in that the profiling operation h) is followed by a finishing operation i) consisting of polishing or sanding the profiled edge resulting from the profiling operation h). 10.- Substrate, in particular a furniture panel, comprising an overmolded edge as obtained by the implementation of the method according to one of claims 1 to 9.