SE528910C2 - Chipboard plate incorporates decorative lowered area and is made of compressed woodchips and sawdust with greater density within area lowered and decorative - Google Patents

Abstract

The chipboard plate incorporates a decorative lowered area and is made of compressed woodchips and sawdust with a greater density within the area lowered and decorative. The plate is produced by application of the wood material on a first pressed cushion, movement of this cushion and a second such cushion towards each other by means of a drive unit. The second press cushion incorporates a projecting component corresponding to the shape of teh decorative lowered area. After the two cushions have been finally pressed together, they are then separated and the formed plate, as a completed product, is removed.

Description

20 25 528 910 Press molding of chipboards today occurs according to various methods to achieve relief or pattern in a surface layer. No board, however, consists of a traditional simple chipboard with a deeper distinct decorative recess over a larger area of the board, for imitation of, for example, a mirror of a mirror door. On the other hand, there is milling out of decorative recesses in chipboard. However, the surface must be machined with a surface layer, as the surface has a rough appearance due to the coarser wood chips compared to the finer wood fibers in an MDF type board.

Document US 4812188 discloses a method of providing doors with mirrors (decorative recess). The method is based on making thin boards of wood shavings, which can be clad with, for example, veneers, which boards are produced with a desired profile in their cross section. Document US 3793125 shows a method in which a middle chip layer of coarser glued chips (L <10 mm) is enclosed by a smaller chip layer (diam. <0.1 mm) of glued chips. The chip layers are applied to each other and then dry pressed. The pre-pressed chipboard is surrounded by patterned decorative paper impregnated with adhesive for hardening, which provides relief in the surface layer mimicking the spread of natural wood. DE 2615661 shows a chipboard with patterned veneer on both sides.

The disadvantages of known boards, such as the above-mentioned MDF with decorative recess, are solved by the board described in the introduction, characterized by the characterizing part of claim 1. Thus, a board, suitable for use as a finished product such as a cabinet door, kitchen door, wardrobe door, sliding door, table top, front, etc., has been provided, which board has a decorative recess imitating, for example, a mirror. The depression or recess in one surface plane (surface layer) (or both surface planes) is made so deep that there is a clear marking of an artistic framework, a recess or other decorative depression. By using wood chips as wood material, cost efficiency is achieved in the manufacture, handling and transport of the board. When manufacturing the board / boards, one and the same spreading device generating an even chip mat with glued wood chips can be used. 10 15 20 25 30 528 910 The plurality of press pads of different appearance with respect to external dimensions and projecting means for providing different types of recesses in the discs can also be used in one and the same press device according to a modular system and in a manufacturing step according to a chip separation process. Before the compression, the chip mat is mainly ironed, which is cost-effective from a manufacturing point of view. Since the density of the wood material due to the compression becomes larger in the area of the recess than in the other part of the board, the strength is greater in this thinner area of the board which is defined by the decorative dry sink of the board.

Preferably, the wood chips are of finer chip size in the at least one surface layer of the board than in a layer intermediate to the board.

In this way, a smooth and even surface is achieved in the transition between the surface of the decorative dry sink and the other surface of the board.

The wood chips are suitably of both finer and coarser chip size in a chip layer intermediate to the board.

Thus, the intermediate layer of the board (intermediate chipboard) is made stronger, whereby the board in the area of the decorative drying depression can be made even stiffer due to the higher density of wood chips.

Alternatively, the disc is mechanically separable from at least one second disc.

In this way, a “cake” consisting of a number of continuous discs can be manufactured in a compression step. The discs can either be separated from each other already in the compression step or sawn apart (cut apart, broken according to the instructions recessed between the discs obtained in the compression step). By having a press pad, with projecting elements for providing a lowered instruction, automatically precisely mark the outer edges of the finished disc, the position of the saw cut can be accurately determined for sawing the discs apart. This means a minimal waste of material. By leaving the edge of the board untreated during / after the compression step, glue vapors (glue that the wood chips have previously been coated with) can be evacuated from the edges, which provides a cost-effective manufacture of the board from a time perspective (shorter drying time). After the glued wood shavings have been compressed under heat (for example 140 ° C - 250 ° C), the built-up steam pressure can thus be effectively evacuated and water vapor emanates from the glue.

Suitably, the decorative recess has a depth greater than the thickness of a surface layer (chipboard) arranged for the board.

Thus, a marked depression in the board has been achieved, which contributes to making the board more similar to, for example, a homogeneous wooden door with a mirror and frame. In case the upper chip layer (surface layer) consists of wood chips of a smaller chip size, the applicant for the present patent has observed in experiments that this surface layer effectively covers the coarser wood chips constituting the intermediate chip layer in the area of the transition from the decorative recess to the non-countersunk area.

Suitably the depth of the decorative recess is about 4-8 mm as the upper chip layer (chip size 0, 1-2.0 mm) has a thickness of about 6-10 mm (before compression) and the shape 3-7 mm (after completion of compression ).

Preferably, the surface layer of the sheet comprises a decorative foil.

This allows the board to mimic any type of wood in appearance. The decorative foil, such as for example a relief paper or thin veneer sheet, is suitably applied to the chipboard before the compression of the board (chipboard). Color powder varnish can also be used for decoration, which varnish is distributed on top of and / or under the chip night before compression. Melamine-impregnated foil or laminate can also be used to advantage. 10 ~ 15 20 25 30 528 910 Alternatively, the board has rounded edges and the wood material has a greater density within the area of the respective rounded edge.

In this way, the edge of the disc can be machined already in the compression step.

The edge also automatically obtains greater strength due to the greater density of wood chips in the press-shaped edge. This is also desirable because edges tend to be exposed to blows to a greater extent than other parts of the disc.

The disadvantages of known methods for manufacturing boards, such as the above-mentioned MDF with decorative recess, are solved by the method described in the introduction, characterized by the steps included in claim 8. Thus, in the manufacture of the board / boards, one and the same spreading device generating an even chip mat with glued wood chips can be used. The majority of press pads with different appearances regarding dimensions and projecting means for producing different types of dry depressions in the discs can also be used in one and the same press device according to a modular system and in a manufacturing step, which is cost-effective. Since the density of the wood material is greater in the area of the recess than in the rest of the board, the strength is greater in this thinner area as they are av niered by the decorative recess of the board due to the fact that the chip mat for compression has a substantially uniform thickness.

This thinner area becomes more compacted and has a higher density than other areas. Alternatively, a continuous press or a clock press can be used.

Suitably the first press pad comprises a projecting member corresponding to the shape of a decorative recess.

Thus, both sides of a board in a single manufacturing step can be provided with decorative recesses.

Preferably, the wood chips are heated by means of a heat generating means of the pressing device. 10 15 20 25 30 528 910 Thus, temperatures higher than room temperature can be used to produce a board glued together of wood chips. By means of a control device, the friend for compression can be set according to desired glue melting points and compression times. Glued wood shavings can, as mentioned above, be compressed under heat of around 140 ° C - 250 ° C, depending on the type of glue and depending on the compression time, which in turn depends on the thickness of the board. In general, one can count as an example with about 6-18 seconds per mm thickness.

Alternatively, when the compression pad is in the position for substantially complete compression of the wood chips, the compression step also includes mechanical separation of at least two boards from each other.

In this way, a “cake” consisting of a number of continuous discs can be manufactured in a compression step. The discs are separated from each other already in the compression step, which is cost-effective.

The wood chips are suitably applied to the first press pad in such a way that wood chips of finer chip size form at least one surface layer (lower chip layer) and wood chips of coarser chip size form an intermediate chip layer.

Thus, the board can be made lighter and with less wood chips, which is cost effective. The intermediate layer can suitably consist of non-separated wood chips (ie a chip fraction with coarser and narrower chips). It will also be easier to separate slices from the above-mentioned "cake" with designated edges. The surface layers suitably consist of separated wood chips, which gives a homogeneous surface layer after compression. This allows the surface of the decorative recess to be smooth and fine.

Preferably, the pressing device comprises a folding pad comprising fastening means for mounting a number of pressing pads. 10 15 20 25 30 528 910 Thus, traditional pressing devices such as, for example, a hydraulic press can be used. The pressing device suitably comprises a fixed pad (fixed plate) attachable to the pressing device by means of stirrups. The press pads (mold plates) (designed based on desired disc designs and customer requirements) are fixed detachably by means of, for example, screws to the fixed pad. Thus, the number of discs can be manufactured in one and the same pressing step according to a modular system.

SUMMARY OF THE FIGURE The present invention will now be explained in more detail with the aid of the accompanying drawings, in which: Figure 1 schematically shows a chip mat for compression; Figure 2 schematically shows according to a first embodiment removed by the press pad in fi g. 1 from a finished board with a smaller chip size in the surface layer; Figure Za schematically shows the edge area of the disc in fi g. 2; Figure 3 schematically shows a second embodiment of a modular system and instructions for separating discs from each other; Figure 4 schematically shows a cake with two slices with instructions provided by the modular system in Figure 3; Figure 5 schematically shows a panel with a distinct recess or similar to a mirrored door with frame; Figure 6 schematically shows a second press pad for manufacturing the disc of Figure 5; Figure 7 schematically shows a fixed pad with mounted press pads; Figure 8 schematically shows a clock press for manufacturing discs according to a third embodiment; and Figures 9a-9d schematically show a spreading machine for distributing chips of different chip sizes forming a chip mat before compressing into a disc according to a fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION The present invention will now be explained with reference to the figures.

Details which are not relevant to the invention are not included for the sake of clarity.

Figure 1 shows a chip mat 1 comprising a lower chip layer 3 comprising glued wood chips 4 (shown in Figure 4) with mainly chip size 1 mm - 2 mm, i.e. a smaller chip size, spread evenly on a litter (a first press pad 6). An intermediate chip layer 5, with a coarser chip size, is spread on the lower chip layer 3. An upper chip layer 7 comprising wood chips corresponding to the chip size of the lower chip layer is spread on the intermediate chip layer 5 with a thickness t1. The three chip layers 3, 5 and 7 thus consist of wood material 10 consisting of glued wood chips 4 which are applied to the first press pad 6 and which wood chips 4 form a desired sheet 8 after hot pressing.

A pressing plate (a second pressing pad 11) of metal is releasably attached to a mounting plate (mounting pad 9) of a pressing device 13. In order to provide a decorative recess 2 in the disc 8, a drive means 15 provides a dry surface of the second press pad 11 against the first press pad 6 until the press pads 6 and 11 are in a position for completed compression molding. The compression molding can alternatively take place by the first press pad 6 being moved towards the second press pad 11.

The second press pad 11 comprises projecting means 17 corresponding in reverse to the decorative recess 2 in the disc 8. Compression to provide the decorative recess 2 is completed when the protruding member 17 of the press pad 11 has compressed the chip layers 3, 5, 7 so much that 7 upper side 19 ended up in the direction of compression below the underside 21 of the upper chip layer 7. Figure 2 schematically shows, after the first and second press pads 6 and 11 are in the position of final pressing of the wood chip 4, how the drive means 15 of the press device 13 move the second press pad 11 in the direction from the first press pad 6 to the exposed disc 8. In figure 2 (partial section) is also shown schematically in magnification the transition 23 from the bottom of the decorative recess 2 (= the upper side 19 of the upper chip layer 7) to the non-recessed area of the disc 8. The decorative recess 2 thus has a depth d which is greater than the thickness T of the compressed upper chip layer 7.

The upper chip layer 7 (surface layer) consists of wood chips of finer chip size. The applicant has observed in experiments that this surface layer, after the compression step, effectively covers the coarser wood chips in the intermediate chip layer within the area of the transition from the decorative recess to the non-recessed area. The depth of the decorative recess is about 4-8 mm as the upper chip layer (chip size 0.1-2.0 mm) has a thickness of about 6-10 mm (before compression) and about 3-7 mm (after completion of compression).

The second pressing pad 11 comprises projecting elements 25 for mechanical separation of the disc 8 from the wood material 10 surrounding the disc 8 or of an adjacent pre-pressed disc. Such a press pad 11 is used for the manufacture of discs 8 which are separated from each other at the end of the compression step. That is, when the press pads 11 are in a position for substantially complete compression of the wood chips 4, a mechanical separation of at least two boards 8 from each other also takes place.

Figure 2a schematically shows an edge area 27 of a board 8 with a homogeneous non-separated chip layer with wood chips 4 of different chip size g °, g ”according to a second embodiment. The chip mat 1 has been coated with a decorative foil 29, such as a plastic foil, before the compression step. The wood chips 4 of the edge area 27 and the superimposed decorative foil 29 form a rounded edge 28 at the compression step, whereby the board 8 automatically has a greater density within the edge area 27 and the rounded edge 28 28, as the wood chips 4 become more tightly packed here ( see reference P). This contributes to higher strength in the edge area 27, which is desirable since the edges of the disc 8 are extra sensitive to impact. The projecting element 25 in ñgur 2 causes a harder compression of the wood chips 4 in the edge area 27, whereby the distance L (= the thickness of the board) becomes greater than the distance L ”.

Figure 3 schematically shows a pressing device 13 for compression molding of adjacent sheets 8. The pressing device 13 comprises a fastening pad 31 comprising fastening means 33, such as clamps 35. Before the fixed pad 31 is mounted to the pressing device 13 by means of the clamps 35 screws 37 two upper metal press pads 11 at the mounting pad 31.

The press pads 11 are manufactured in accordance with the wishes of one or more customers of the type of finished board 8. In a compression step, according to the modular system provided, your designs of finished boards 8 can be manufactured. Heat generating means 39 are arranged at the pressing device 13 for heating the glued wood chips 4 during compression with a temperature of 140 ° C - 250 ° C, preferably 160 ° C - 220 ° C, so that the curing properties of the adhesive complete the board 8 fixed ( hard) structure. Protruding elements 25 of the second press pads 11 are arranged to provide in the compression step an instruction 41 which marks the outer dimensions of the discs 8 (edges 8 of the disc 8), which instruction 41 also further simplifies mechanical separation of the discs 8 from each other. The mechanical separation can take place by means of buckling, sawing, etc. of wood material 10 forming waste material 42. Figure 3 schematically shows the finished pressed discs 8 and how the fastening pad 31 is moved in the direction from the first pressing pad 6 after completed compression step.

The depth provided by the projecting elements 25 in the disc can be half the thickness of the disc.

Figure 4 schematically shows how a cake 43 has been completed comprising the two discs 8 in accordance with the compression step shown in figure 3. According to this embodiment, the discs are built up of an intermediate chip layer 5 and a lower chipboard upper chip 7. ) and the total thickness S for other area 46 is greater than the thickness S 'for said area 45.

Figure 5 schematically illustrates a disc 8 with a distinct decorative recess 2 mimicking a mirror door with frame 47. According to a cross section II of the disc 8 the profile 8 shows the corresponding profile of a purpose-made second press pad 11 in Figure 6. The projecting means 17 for providing the illusory mirror (decorative recess 2) of the disc 8 is arranged to compress at least one third of the surface area of the chip mat with greater compression than other area 46. To the projecting means 17 connect four pieces (of which two are shown) projecting means 17 "and 17" of the press pad 11 for making notches 49 (see Figure 5) in the disc 8 for marking the joint of the illusory wooden frame 47.

Figure 7 schematically shows a mounting pad 9 detachably attached to a pressing device 13.

According to the modular system, six press pads II are mounted on the fastening pad 9 for the production of three different types of board. Based on the customer's wishes, press pads for new boards, during the production of already ordered boards, can be completed and mounted on a second fixed pad (not shown). A modular system has been provided which has the advantage of providing both discs 8 in a single compression step, and of saving time in the production line since fastening pads 9 for new types of discs 8 can be prepared without having to interrupt production.

Figure 8 schematically illustrates a clock press 50 for manufacturing discs 8 according to a third embodiment. These discs comprise decorative door depressions 2 on both sides of the disc 8. The first press pad 6 thus also comprises the projecting member 17. Mounting pads 31 with screwed press pads (press bands) 6 are placed on each other in stacks for compressing four pieces of chip mats (not shown) . In this way, a large number of discs 8 can be produced in a single compression step, which is cost-effective.

The method of manufacturing a board 8 in the pressing device 13 shown in Figure 8, by compressing mainly wooden material 10, wherein the board 8 comprises at least one decorative recess 2, takes place by first applying the wooden material 10, consisting of glued wood chips 4, to at least the first The press pad 6. Then, by means of the drive means 15, the second press pad 11 is moved towards the first press pad 6. Both the first 6 and the second 11 press pad comprise projecting means 17 with the shape inverted corresponding to the desired decorative recess 2. The movement takes place (the compression step) until the pressing pads 6 and 11 are in position for final compression of the wood chips 4 and the projecting means 17 have formed the decorative drying depressions 2. Thereafter the pressing pads 6 and 11 are separated from each other by means of the drive means 15 for releasing the disc 8 (the discs 8), which removed from the press device 13 and cooled.

The board can then be used as a finished product in a piece of furniture. This finished product is lighter and has a lower manufacturing cost than MDF-type boards.

In connection with Figures 9a-9d, a method will now be described for producing a chip mat 1 (board 8) built of glued wood chips 4 of finer chip size in the lower chip layer 3 and upper chip layer 7 of the board 8, and of wood chips 4 of both coarser and lower chip sizes. in the intermediate layer of the disc. This is achieved by applying the lower 3 and upper chip layer 7 in two layers A and B after mechanical separation of the wood chips 4 with supplementary air separation. The separation can only take place mechanically as well. A first press pad 6 is moved by means of drive means (not shown) in the direction of the arrow p '. Separation rollers 52 with different circumferences and at different mutual distances are rotated counterclockwise. Glued wood chips 4 are fed from a chip feed unit (not shown) over the separation rollers 52, which separate the wood chips 4 so that wood chips 4 of a smaller chip size are first distributed on the press pad 6 forming the layer A. 10 15 20 25 30 528 910 13 coarser chip size forming layer B. An air flow 54 can complete the separation.

When layers A and B fill in the press pad 6, it is moved in the opposite direction according to the arrow p '' which is shown in Figure 9b. Non-separated wood chips 4 are now applied to the layer B so that a third layer C is provided. A fourth layer D of non-separated wood chips 4 is then applied again, but according to the direction of the arrow p '", as shown in Figure 9c.

Wood chips 4 of both finer and coarser chip size constitute the intermediate chip layer 5 provided for the board (the third and fourth layers C and D).

Finally, the press pad 6 is moved according to the p '° direction of the arrow shown in Figure 9d. Since this direction p "°" is opposite to the direction shown in Figure 9a, wood chips 4 of coarser chip size will first be distributed on the fourth layer D forming a fifth layer B ".

As the press pad 6 is moved according to the arrow p "" ° direction, separated wood chips 4 of a smaller chip size are also applied to the layer B "forming a sixth layer A". This separation can also be supplemented with an air flow 54.

The finished chip mat 1 consisting of layers A, B, C, D, B "and A" then undergoes a compression by means of a second press pad (upper) 11l comprising a projecting member 17 (not shown). The wood chips are heated during compression so that the curing properties of the glue complete the solid (hard) structure of the board 8.

By not separating the wood chips for the middle layer (C and D), the board 8 is achieved a greater strength due to the larger center density.

The present invention is not to be construed as limited to the embodiments described above, but also combinations of these and other embodiments exist within the scope of the appended claims. For example, the surface layer of the board can be provided with a decorative foil with relief such as plastic foil, melamine impregnated foil, different types of primer foil, etc. Application of surface veneer and direct varnishing can also be arranged in the surface layer to create an aesthetically pleasing surface layer. The present 528 910 14 invention provides cost-effective finished panels for doors, fronts, mirrored doors and other finished panels with a distinctive decorative recess.

Claims (1)

1. 0 15 20 25 30 528 910 ISV i PArENrKRAv. Sheet made up mainly of wood material (10), the board (8) comprises at least one decorative recess (2), the wood material (10) consists of compressed wood chips (4), the wood material (10) has a higher density in the area of the decorative recess ( 2), characteristics! in that the wood chips (4) are of a smaller chip size in the board (8) of at least one surface layer than in a layer intermediate to the board, so that trä wood chips cover the coarser wood chips within the transition from the decorative recess (2) to a non-recessed area. . Disc according to Claim 1, characterized in that the wood chips (4) are of both a narrower and coarser chip size in a chip layer (5) intermediate to the board. . Disc according to one of Claims 1 or 2, characterized in that the disc (8) is mechanically separable from at least one second disc. . Disc according to one of the preceding claims, characterized in that the decorative cover (2) has a depth (d) greater than the thickness (T) of the surface layer of the disc. . Disc according to one of the preceding claims, characterized in that the surface layer of the disc (8) comprises a decorative foil (29). . Board according to one of the preceding claims, characterized in that the board (8) has rounded edges (28) and in that the wood material (10) has a greater density within the area of the respective rounded edge (28). . Method for manufacturing a board (8) comprising at least one decorative drying sink (2) by compressing mainly wooden material (10) by means of a pressing device (13) comprising a drive means (15), the method is characterized by the steps; Applying the wood material (10), consisting of glued wood chips (4), to a first press pad (6) in such a way that wood chips (4) of a smaller chip size form at least one surface layer and wood chips (4) of coarser chip size forms an intermediate chip layer (5) - floating of the first press pad (6) and a second press pad (1 l) against each other by means of the drive means (15), the second press pad (6) comprises a projecting member (17) corresponding to the shape of the decorative liner (2), until the press pads (6, 11) are in a position to complete compression of the wood chips (4) and the projecting member (17) has formed the decorative liner (2); - separating the press pads (6, 1 1) from each other by means of the drive means (15) for releasing the disc (8); removal of the disc (8) from the pressing device (13). A method according to claim 7, wherein the first press pad (6) comprises a protruding member corresponding to the shape of a decorative liner (2). Method according to claim 7 or 8, wherein the wood chips (4) are heated by means of a heat-generating means (39) of the pressing device (13). A method according to any one of claims 7-9, wherein the compression step, when the press pads (6, 11) are in a position for substantially completed compression of the wood chip (4), also comprises mechanical separation of at least two boards (8) from each other. A method according to any one of claims 7-10, wherein the pressing device (13) comprises a fastening pad (31) comprising fastening means (33) for mounting a number of pressing pads (6, 11).