IES980088A2 - Apparatus and method for manufacturing furniture - Google Patents

Abstract

Preformed natural wood panels of preselected sizes are prepared at a preparation station (40). Selected panels are delivered through an apparatus (1) for applying a smooth edge profile to the panels. The panels are delivered through a sanding machine (41) for sanding a top face of the panels, that is the face that when in use will be outwardly facing and exposed to view. Downstream of the sanding machine (41), the panels are passed to a loading station (42). At the loading station (42), the panels are mounted on a conveyor (44) which carries the panels through a sanding and polishing station (45) prior to delivery of the panels to a spraying booth (46) for applying a lacquer to the panels. Downstream of the spraying booth (46), the panels are loaded on mobile racks (50) which are delivered by an endless conveyor (52) through a drying tunnel (53). A number of lacquer coats are applied to the panels which are then build into furniture products.<Fig.12>

Description

Apparatus find Method for Manufacturing Furniture Introduction This invention relates to an apparatus and method for manufacturing furniture.

The invention is particularly concerned with the mass production of furniture made from a natural wood material. A problem with the manufacture of natural wood furniture arises from the nature of the grain structure of the wood. Thus, when machining or cutting the wood, particularly across the grain, the machined face tends to be rough and requires smoothing by sanding for example. The additional time spent in delivery of the panel from the cutting or moulding machine to a sander and finishing the edge in the sander increases production time and cost. This is not significant when producing high quality furniture from natural wood in low volumes. However, it is a major problem for high volume production. Thus, in recent years there has been a movement away from natural wood in the mass production of furniture towards medium density fibre board (MDF) which is much easier to handle and machine. There is no problem with grain structure in MDF and for this reason is has become popular with high volume furniture manufacturers. However, it does not have the same appeal as natural wood.

It is an object of the present invention to provide apparatus and a method which facilitates the mass production of furniture made from a natural wood material.

Statements of Invention ——£-··· '............

OPEN TO PUBLIC INSPECTION UNDER SECTION 28 AND RULE 23 BNSDOCID; IE 980088 - 2 According to the invention, there is provided an apparatus for the manufacture of natural wood furniture comprising:clamp means for gripping and supporting a panel, conveyor means for delivering said panel through two 5 complementary machining stations, a guide rail associated with the conveyor means for engagement with the panel to deliver the panel in a desired orientation through the machining stations, the machining stations comprising a cutting station 10 and an associated sanding station downstream of the cutting station, the cutting station having a shaped cutter blade for engagement with an edge of the panel for cutting a desired shaped profile along the edge of the panel, and a sanding station having a complementary shaped sanding head for engagement with and sanding of said profiled edge of the panel.

In a preferred embodiment the invention provides apparatus 20 for the manufacture of natural wood furniture comprising:an edge profiling apparatus for forming a smooth shaped edge on a natural wood panel, the edge profiling apparatus comprising clamp means for gripping and supporting a panel, conveyor means for delivering said panel through to complementary machining stations, OOCID: - 3 IE 980088 a guide rail associated with the conveyor means for engagement with the panel to deliver the panel in a desired orientation through the machining stations, the machining stations comprising a cutting station and an associated sanding station downstream of the cutting station, the cutting station having a shaped cutter blade for engagement with an edge of the panel for cutting a desired shaped profile along the edge of the panel, and a sanding station having a complementary shaped sanding head for engagement with and sanding of said profiled edge of the panel; a polishing station having means to prepare a surface of wooden panels for reception of a lacquer or paint coating composition; a spray booth for spraying a liquid coating composition onto panels; a drying station for drying the coating composition on the panels; and an assembly station for assembly of a set of panels to form a wooden furniture.

Preferably, the cutter blade is shaped for extension around an outer edge of the panel to engage and shape the outer edge of the panel.

IE 980088 - 4 In one embodiment of the invention, the position of the cutter blade relative to the guide rail is adjustable. Preferably, the cutter blade is mounted on a carriage which is movable on a support towards and away from the guide rail.

In another embodiment of the invention, the carriage is height adjustable on the support.

In one embodiment of the invention, the position of the sander relative to the guide rail is adjustable. Preferably, the sander is mounted on a carriage which is movable on a support towards and away from the guide rail. Most preferably, the carriage is height adjustable on the support.

In a further embodiment of the invention, the conveyor means comprises an associated pair of spaced-apart substantially parallel conveyors which are engagable with opposite sides of the panel inboard of side edges of the panel, each conveyor being of two-part construction having a fixed lower part and a movable upper part, said conveyor parts forming the clamp means for gripping a panel therebetween, the conveyor parts being engagable with bottom and top faces of the panel.

In another embodiment of the invention, the conveyors comprise an inner fixed conveyor and an outer movable conveyor which is movable towards and away from the fixed inner conveyor. Preferably, a dust extraction duct is provided at each machining station, the duct having an inlet end connected to each machining station, and means to apply a vacuum to the duct for dust extraction through the duct.

IE 980088 - 5 In a preferred embodiment the drying station comprises an endless conveyor for releasable engagement with and movement of a wheeled panel carrying rack through a drying tunnel, the drying tunnel having means for generating and delivering a heated air stream through the drying tunnel.

In a particularly preferred embodiment the conveyor comprises an endless belt driven in a support panel, a plurality of spaced-apart upstanding rack drive pins on the belt which are releasably engagable with an associated hook on each wheeled rack.

The invention also provides a method for manufacturing natural wood furniture comprising the steps:preparing a number of natural wood panels of preselected sizes, delivering selected panels through the edge profiling apparatus for forming a desired shaped profile along one or more edges of each panel, sanding an outer face of the panels, polishing the outer face of the panels, spraying lacquer onto the outer face of the panel, drying the lacquer on the panels, and assembling sets of panels to form a furniture item.

In another embodiment of the invention, the method includes the step of spraying a stain onto the panels prior to applying lacquer to the panels.

IE 980088 - 6 Preferably, the drying is carried out by mounting the panels on a mobile rack, delivering the rack through a drying tunnel, generating a drying airstream within the tunnel through which the rack travels by discharging hot air from outlets on an inner side face of the tunnel and extracting air through a top of the tunnel.

Most preferably, the racks are delivered along a drying path downstream of the drying tunnel for additional drying of the panels in ambient air.

Detailed Description of the Invention The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:Fig. 1 is a perspective view of an edge profiling apparatus according to the invention; Fig. 2 is another perspective view of the apparatus; Fig. 3 is a further perspective view of the apparatus; Fig. 4 is a plan view of the apparatus; Fig. 5 is a detail perspective view of a sanding station portion of the apparatus; Fig. 6 is a perspective view of a wood panel prior to shaping in the apparatus; Fig. 7 is a detail sectional elevational view of portion of the conveyor of the apparatus; - 7 IE 980088 Fig. 8 is a detail sectional elevational view of a cutting station portion of the apparatus; Fig. 9 is a detail sectional elevational view of a sanding station portion of the apparatus; Fig. 10 is an exploded view of a sanding head used in the sanding station; Fig. 11 is a plan view of the sanding head; Fig. 12 is a schematic layout of a production system for manufacturing furniture according to the invention; Fig. 13 is a detail perspective view showing a drying rack used in the production system; Fig. 14 is an end elevational view of the drying racks; and Fig. 15 is a detail perspective view showing engagement of the rack by an associated conveyor.

Referring to the drawings, and initially to Figs. 1 to 11, there is shown apparatus according to the invention, indicated generally by the reference numeral 1 for edge profiling of wood panels. The apparatus 1 has a groundengaging bed 2. A pair of spaced-apart substantially parallel conveyors 3, 4 are mounted on the bed 2. The conveyors 3, 4 are operable to engage and clamp a wood panel and deliver the panel through a cutting station 5, 6 and a complementary sanding station 7, 8 associated with each conveyor 3, 4. Each sanding station 7, 8 is located downstream of it's associated cutting station 5, 6.

BNSDOCID: IE 980088 - 8 The conveyors 3, 4 comprise an inner fixed conveyor 3 and an outer movable conveyor 4 which is mounted on a carriage 10 for movement on the bed 2 towards and away from the inner fixed conveyor 3 for adjustment of the spacing between the conveyors 3, 4 to accommodate panels of different width.

Each conveyor 3, 4 is of two-part construction having a fixed lower part 14, 15 and a movable upper part 16, 17. Both conveyor parts 14, 15, 16, 17 are mounted on an associated upstanding post 18, 19 mounted on the bed 2 and the carriage 10 respectively. Each of the upper conveyor parts 16, 17 is slidable vertically on its associated support post 18, 19. This allows for adjustment of the spacing between the lower part and upper part to accommodate panels of different thickness. The upper part and lower part effectively clamp the panel therebetween inboard of side edges of the panel, the side edges projecting outwardly of the conveyors 3, 4 for machining at the cutting station 5, 6 and sanding station 7, 8. Each conveyor part 14, 15, 16, 17 has an endless conveyor belt driven by an electric motor through a drive transmission.

A guide rail 9 is associated with the fixed inner conveyor 3 and extends alongside the conveyor 3 for engagement with a panel 20 to deliver the panel in a desired orientation through the cutting station 5 and sanding station 7. The panel 20 engages against and slides along the guide rail 9.

Each cutter station 5, 6 has a rotary cutter head 22 with a plurality of spaced-apart cutter blades 23. A cutting edge 24 of each blade 23 is shaped to impart a desired profile 26 to an edge of the panel 20. It will be noted IE 980088 - 9 that the cutter blade 24 curves inwardly around an outermost portion 25 of the edge so that the outermost portion 25 of the edge is rounded and smooth so that when in use the outermost edge 25 does not catch or snag clothing or the like.

Fig. 9 shows the sanding station having a rotary sanding head 28 with a number of radial sanding blocks 29 shaped to correspond with the cutting blade 23 to put a smooth finish on the profiled edge of the panel 20.

In use, a panel 20 is mounted at an inlet end of the conveyors 3, 4 with an edge of the panel engaging the guide rail 9. Upon being gripped by the conveyors 3, 4, the conveyors 3, 4 deliver the panel past the cutting station 5, 6 and then past the sanding station 7, 8 to impart a desired profile to the edge of the panel. Advantageously a smooth edge profile is accurately and quickly achieved. It will be noted that the edge profile may be provided on one edge of the panel, by retracting the cutter 6 and sander 8, or on two opposite edges of the panel 20.

Fig. 12 shows schematically a method and apparatus for manufacturing wooden furniture according to the invention.

Preformed wooden panels 20 of preselected sizes are prepared at a preparation station 40. Selected panels are delivered through the apparatus 1 for edge profiling. The panels are delivered through a sanding machine 41 for sanding a top face of the panels, that is the face that when in use will be outwardly facing and exposed to view. Downstream of the sanding machine 41, the panels are passed to a loading station 42. At the loading station 42, the panels are mounted on a conveyor 44 which carries the panels through a sanding and polishing station 45 BNSDOCID; IE 980088 - 10 prior to delivery of the panels to a spraying booth 46. As the panels are carried on the conveyor 44 through the spraying booth 46, a stain is sprayed on the panels. Downstream of the spraying booth 46, the panels are carried through a fume extractor 48 before being loaded on mobile racks 50. Advantageously a high quality finish is achieved on the faces of the panels.

Each rack 50 is wheeled over to and connected up to an endless conveyor 52 which wheels the rack 50 through a drying tunnel 53. Within the drying tunnel 53, a drying air stream is generated by discharging hot air from outlets on an inner side face of the tunnel 53 and extracting air through a top of the tunnel 53. Downstream of the drying tunnel 53, the conveyor 52 delivers the racks along a drying path 55 for additional drying of the panels. As the racks 50 approach the loading station 42, they are disengaged and delivered to the loading station 42.

At the loading station 42, the panels are transferred from the rack 50 onto the conveyor 44 for a second pass through the sanding and polishing station 45 prior to being sprayed with a lacquer in the spray booth 46. After fume extraction, the lacquered panels are again loaded on a rack 50 for delivery through the drying tunnel 53 as previously. This cycle may be repeated two or three times to achieve the desired high class finish on the panels. At the end of the lacquering process, the racks with the finished panels are delivered to an assembly station where sets of panels are assembled to form furniture items.

Referring to Figs. 13 to 15 the arrangement of the racks 50 and conveyor 52 is shown. Each rack 50 has a metal frame 60 mounted on casters 61. The frame 60 has a base 62 with upstanding posts 63 along one side of the base 62. - 11 IE 980088 Each post 6 3 has a plurality of vertically spaced-apart arms 65 extending outwardly over the base 62 on which the panels 20 are mounted. A hook 67 is mounted on a side of the base 62 for engagement with an associated pin 69 on the conveyor 52. The conveyor 52 has an endless belt 70 driven in a support channel 71. A number of spaced-apart upstanding pins 69 project upwardly of the belt 70 for engagement with the hook 67 of each rack 50. Thus the rack 50 can be easily engaged and disengaged with the conveyor 52. Rollers 72 on the base 62 of the rack are engagable with a side of the channel 71 to guide the rack around curved ends 74, 75 of the conveyor 52. Each hook 67 is removably mounted on the rack 50 by means of tubular mounts 77, 78 which engage with associated pegs 79, 80 on the base 6 2 of the rack 50. Thus the hook 67 can be removed prior to delivery of the rack to the assembly station to prevent snagging or damage by the hook 67.

Preferably the natural wood panels are composite panels comprising a number of strips of natural wood (typically 50mm wide) joined edge to edge to form the composite panel. This provides a panel which has much greater resistance to warping than a one-piece panel.

It will be appreciated that the invention provides apparatus and a method for the mass production of high quality natural wood furniture.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (5)

1. Apparatus for manufacture of natural wood furniture comprising:an edge profiling apparatus for forming a smooth shaped edge on a natural wood panel, the edge profiling apparatus comprising clamp means for gripping and supporting a panel, conveyor means for delivering said panel through two complementary machining stations, a guide rail associated with the conveyor means for engagement with the panel to deliver the panel in a desired orientation through the machining stations, the machining stations comprising a cutting station and an associated sanding station downstream of the cutting station, the cutting station having a shaped cutter blade for engagement with an edge of the panel for cutting a desired shaped profile along the edge of the panel, and a sanding station having a complementary shaped sanding head for engagement with and sanding of said profiled edge of the panel; a polishing station having means to prepare a surface of wooden panels for reception of a lacquer or paint coating composition; IE 980088 - 13 a spray booth for spraying a liquid coating composition onto panels; a drying station for drying the coating composition on the panels; and an assembly station for assembly of a set of panels to form a wooden furniture product.

2. Apparatus for manufacture of natural wood furniture substantially as hereinbefore described with reference to the drawings.

3. A method for manufacturing natural wood furniture comprising the steps:preparing a number of natural wood panels of preselected sizes, delivering selected panels through the edge profiling apparatus for forming a desired shaped profile along one or more edges of each panel, sanding an outer face of the panels, polishing the outer face of the panels, spraying a lacquer or paint coating composition onto the outer face of the panel, drying the coating composition on the panels, and assembling sets of panels to form a wooden furniture product. IE 980088 - 14

4. A method for manufacturing natural wood furniture substantially as hereinbefore described with reference to the accompanying drawings.

5. Natural wood furniture whenever produced by the 5 method as claimed in any preceding claim.