US3396064A - Continuous laminating method and apparatus - Google Patents
Continuous laminating method and apparatus Download PDFInfo
- Publication number
- US3396064A US3396064A US337012A US33701264A US3396064A US 3396064 A US3396064 A US 3396064A US 337012 A US337012 A US 337012A US 33701264 A US33701264 A US 33701264A US 3396064 A US3396064 A US 3396064A
- Authority
- US
- United States
- Prior art keywords
- plies
- adhesive
- range
- resin
- alcohol
- 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.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27D—WORKING VENEER OR PLYWOOD
- B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
- B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
- Y10T156/1702—For plural parts or plural areas of single part
- Y10T156/1744—Means bringing discrete articles into assembled relationship
- Y10T156/1751—At least three articles
- Y10T156/1761—Stacked serially
Definitions
- the plies are coated utilizing a precatalyzed phenolic wet line application technique and adhesive; and are handled in a manner to permit substantially greater production of fibrous panels of improved quality.
- the adhesive is a resorcinol type, alkali catalyzed, spray dried, phenol-formaldehyde resin (synthetics Expand Adhesive Functions by Peter W. Sherwood, published in Hitchcocks Wood Working Digest, page 23, August 1963, Hitchcock Publications, 222. E. Willow, Wheaton, 111.).
- a technique heretofore employed is to cut the dried film to size and insert between the plies to form a sandwich at the time of lay-up.
- This comprises a relative slow process as compared to the technique of the present invention which, in essence, comprises the utilization of a precatalyzed phenolic wet line process having the handling advantages of a dry glue line lay up.
- a crossband or ply 1 is shown moving along a production line or conveyor 2.
- This conveyor in essence comprises two or more continuous strands which are adapted to move the respective plies or crossbands through the respective processing steps.
- ply 1 passes beneath a conventional roll glue spreader 3.
- a precatalyzed phenolic adhesive or glue is applied to both surfaces of the ply, preferably 28 to 37 lbs./ 1000 sq. ft. of single glue States Patent "ice line.
- the formulation of the especially prepared glue or adhesive of the present invention is as follows:
- the pecan or walnut-shell flour is present in order to prevent excessive penetration into the wood during coating and pressing and thus prevent starved glue lines and wasted adhesive.
- the alkali, or catalyst is any suitable alkali solution as, for example, sodium or potassium hydroxide, particularly sodium hydroxide.
- an aliphatic alcohol is added.
- This alcohol may be any suitable low boiling alcohol as, for example, methyl alcohol, ethyl alcohol, isopropyl alcohol or a mixture.
- the alcohol should have from about 1 to 4 carbon atoms in the molecule.
- the wood surface may be readily coated, and a film is formed which acts like a varnish.
- These films may be readily dried under mild heat without accidentally precuring the resin, partly because of the lesser quantity of alkali present and partly because of the less advanced condition of the resin.
- the alcohol present has an additional advantage in that being much more volatile than water, it will be removed more readily and will also be independent of the relative humidity. This greatly aids in the drying since less heat will be required and, accordingly, less danger will exist on precuring of the resin.
- the catalyst or alkali used in the preparation of the adhesive is preferably sodium hydroxide or its equivalent in alkalinity.
- the methanol or other aliphatic alcohol is an essential ingredient.
- these resins must dissolve in a water-alcohol mixture if the results desired by the present invention are to be secured. Resins that will function of the resol type are soluble in water-alcohol mixtures, all alcohol, alcohol acetone mixtures or all acetone, and the like.
- the adhesive is preferably applied at room or ambient temperatures as, for example, in the range from about 68 to 85 R, such as about F
- the ply after having the adhesive applied by spreader or rolls 3, then passes into evaporation zone or area 4 wherein substantially all the solvent is removed.
- evaporation area is meant an unenclosed area or a partially enclosed chamber vented for removal of solvent vapors.
- the Perlon* strands carrying the respective plies along the production line are cooled in evaporation area 4 by means of cooling water or cooling fluid circulated through pipes or conduits 15. This serves to prevent the resin or adhesive from sticking to the conveying strands.
- the solvent is removed by circulating air at a temperature in the range from about 45 F. to 55 F. as, for example, about 50 F. across the top and bottom of the ply.
- a temperature in the range from about 45 F. to 55 F. as, for example, about 50 F. across the top and bottom of the ply.
- the ply after passing through flash Zone 4, then passes into an infrared oven zone wherein both the top and the bottom of the ply are heated by infrared ovens 5 and 6.
- the precatalyzed adhesive is advanced.
- the preferred temperatures for use with respect to ovens 5 and 6 is in the range from about 145 to 175 R, such as 160 to 170 F., and the time period in the range from about to 60 seconds especially in the range from to 50 seconds.
- a preferred method of precuring is at a temperature of about 160 F. for a time period of about seconds.
- the infrared ovens are important. Resols are particularly susceptible to heating by infrared and the drying begins at the bottom of the film, thus getting the solvents out as quickly as possible and with the least danger of precuring. Convection ovens and high-velocity ovens would merely skin over such a varnish coat causing sticking later and perhaps starved glue lines in the pressing operation. While infrared ovens are much preferred, it is understood that advancing may be accomplished by circulating air in heated ovens as, for example, at a temperature in the range from about 145 to 300 F. for a time period in the range from about 30 to 40 seconds.
- the ply or crossband passes through the infrared ovens 5 and 6, it is passed through cooling units 7 and 8 wherein the ply is rapidly cooled to ambient temperature.
- the cooling unit is necessary in order to prevent latent heat from advancing the cure too far; it is desirable to stop the advancement quickly. This is accomplished by circulating cool air cooled by means of cooling water or cooling fluid circulated through pipes or conduits 15, over the top and bottom of the ply or crossband at a temperature in the range from about 0 F. to F., preferably at a temperature in the range from about 20-40 F.
- the cooled plies are then passed to a lay up step 9 wherein the same are manually afiixed one to the other, which is accomplished very effectively and in a relatively short time as compared to the dry film method.
- the laid up unit is then stacked and then fed into the hot press 10 and 11 where they are finally cured, preferably at a temperature in the range from about 280 to 320 F. for a time period in the range from about 3 to 10 minutes.
- the pressures utilized are in the range from about to 200 pounds per square inch.
- a very desirable temperature is in the range from 290 to 310 R, such as about 300 F. for a time period of from 5 to 8 minutes, such as about 6 minutes.
- a very desirable pressure is in the range from about to 175 lbs/sq. in., such as about lbs/sq. in.
- the moisture content of the materials is not as critical as when employing other techniques such as a dry film process.
- the film must be cut to size and inserted between the respective plies at the time of lay up. The present process eliminates this slow technique and the lay up crews are tied in with direct machine line speed.
- the present invention may be understood by the following example illustrating an embodiment of the same.
- Example A phenolic adhesive of the following formulation was prepared: The formula may be somewhat varied depending upon desired viscosity.
- Phenol was reacted with an excess of formaldehyde and a minimum of al ali until a B stage resin was secured. This resin was still soluble in water but not freely so, but quite soluble in water-alcohol mixtures. In general, these resins which are soluble in low boiling alcohols, or acetone and in water-alcohol mixtures are satisfactory. Adhesives that will not function in the present invention are those which are soluble exclusively in strong caustic aqueous mixtures,
- the adhesive after mixing was fed into a conventional top and bottom glue spreader.
- the spreader applied a uniform application of resin to each side of the component passing through the spreader rollers.
- the rate of spread was 28 to 37 pounds of adhesive per thousand square feet of single glue line.
- the spread component emerges from the spreader onto a Perlon or plastic type strand conveyor.
- the conveyor consists of continuous strands, and conventional water cooled attachments cooled by means of cooling water circulating through pipes or conduits 15" (similar to 15 and 15') are positioned where desirable along the operating or the return path to keep the strands cool and thus prevents the adhesive sticking to the strands.
- the spread material was immediately flashed off as described by means of circulating air and then semiadvanced in an infrared oven.
- the infrared oven was 21 feet long and operating at approximately F. for 45 seconds.
- the infrared heating elements are located at the top and bottom of the ovens. As the material emerged from the infrared oven it was immediately cooled in the cooling units.
- the crossbands were then sent to the lay up station and the hot press area as described. Excellent high quality panels of high strengths were secured.
- the spread material may be laid up into a regular door, partition or other plywood constructions and cured as, for example, via the hot press methods at temperature ranges from about 280 F. to 320 F. for about 3 to 10 minutes depending on the depth to the farthest glue line, and at pressures in the range from about 110 to 200 pounds per square inch depending on the particular construction.
- Process for the fabrication of a panel in a fast, substantially continuous process to increase through-put, and increase quality by eliminating starved glue lines consist-- ing of a plurality of plies which comprises the steps of coating said plies with an alkali catalyzed phenol formal dehyde resin present in a solution containing a monohydroxy aliphatic alcohol, removing said alcohol by atmospheric air, thereafter moving said plies by thin con- See footnote at hot-tom of column 3.
- the final bonding is in the range from about 290 to 310 F.
- phenol formaldehyde resin is formed by adding the following weight percentages: phenolic resin 64-21, water 25-45, shell flour 6-14, and methanol 520.
- phenol formaldehyde resin is formed by adding the following Weight percentages: phenolic resin 45, water 33.7, walnut shell flour 11.2, and methanol 10.1
- An apparatus to apply precatalyzed adhesive to a ply in a fast, substantially continuous process to increase through-put, and increase quality by eliminating starved glue lines comprising a conveyor comprising at least two strands of plastic, an adhesive spreader to apply an adhesive to both sides of said ply, an evaporation area to evaporate the low boiling solvent, means to cool the said conveying strands to prevent sticking to the adhesive, infrared ovens to advance the setting of the adhesive, a lay-up area, and a hot pressing means for bonding the assembly together.
- An apparatus as set forth in claim 9 for multiple plies of Wood veneer, and cooling units are used after the infrared ovens to prevent the cure from advancing so far that it reaches its final setting stage.
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Wood Science & Technology (AREA)
- Forests & Forestry (AREA)
- Veneer Processing And Manufacture Of Plywood (AREA)
- Adhesives Or Adhesive Processes (AREA)
Description
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US337012A US3396064A (en) | 1964-01-10 | 1964-01-10 | Continuous laminating method and apparatus |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US337012A US3396064A (en) | 1964-01-10 | 1964-01-10 | Continuous laminating method and apparatus |
Publications (1)
Publication Number | Publication Date |
---|---|
US3396064A true US3396064A (en) | 1968-08-06 |
Family
ID=23318719
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US337012A Expired - Lifetime US3396064A (en) | 1964-01-10 | 1964-01-10 | Continuous laminating method and apparatus |
Country Status (1)
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US (1) | US3396064A (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3915782A (en) * | 1973-03-12 | 1975-10-28 | Nupla Corp | Method of attaching hand grips to fiberglass tool handles |
CZ308034B6 (en) * | 2019-02-08 | 2019-11-06 | Aspara S R O | Process for continuously producing lightweight composite sheet materials |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2482525A (en) * | 1945-10-19 | 1949-09-20 | Westinghouse Electric Corp | Odorless phenol-formaldehyde resinous products |
US2574784A (en) * | 1944-12-26 | 1951-11-13 | Weyerhaeuser Timber Co | Phenolic adhesive and method of bonding wood plies |
GB684860A (en) * | 1949-05-06 | 1952-12-24 | Union Carbide & Carbon Corp | Improvements in or relating to improved alcohol reacted phenol-formaldehyde bonding resins and to bonded laminates of aluminium and cellulosic sheet material |
US2699417A (en) * | 1949-05-06 | 1955-01-11 | Union Carbide & Carbon Corp | Paper-covered aluminum assembly for bonding to plywood |
US2885068A (en) * | 1956-03-26 | 1959-05-05 | Gordon W Bishop | Cleaning and de-waxing devices for conveyors |
US3008907A (en) * | 1959-03-04 | 1961-11-14 | American Marietta Co | Thermo-setting phenol-aldehyde resin adhesive composition, extender base therefor, and method of preparing same |
-
1964
- 1964-01-10 US US337012A patent/US3396064A/en not_active Expired - Lifetime
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2574784A (en) * | 1944-12-26 | 1951-11-13 | Weyerhaeuser Timber Co | Phenolic adhesive and method of bonding wood plies |
US2482525A (en) * | 1945-10-19 | 1949-09-20 | Westinghouse Electric Corp | Odorless phenol-formaldehyde resinous products |
GB684860A (en) * | 1949-05-06 | 1952-12-24 | Union Carbide & Carbon Corp | Improvements in or relating to improved alcohol reacted phenol-formaldehyde bonding resins and to bonded laminates of aluminium and cellulosic sheet material |
US2699417A (en) * | 1949-05-06 | 1955-01-11 | Union Carbide & Carbon Corp | Paper-covered aluminum assembly for bonding to plywood |
US2885068A (en) * | 1956-03-26 | 1959-05-05 | Gordon W Bishop | Cleaning and de-waxing devices for conveyors |
US3008907A (en) * | 1959-03-04 | 1961-11-14 | American Marietta Co | Thermo-setting phenol-aldehyde resin adhesive composition, extender base therefor, and method of preparing same |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3915782A (en) * | 1973-03-12 | 1975-10-28 | Nupla Corp | Method of attaching hand grips to fiberglass tool handles |
CZ308034B6 (en) * | 2019-02-08 | 2019-11-06 | Aspara S R O | Process for continuously producing lightweight composite sheet materials |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: U.S. PLYWOOD CORPORATION, A CORP. OF DE. Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:CHAMPION INTERNATIONAL CORPORATION A CORP OF NEW YORK;REEL/FRAME:004476/0458 Effective date: 19850828 Owner name: U.S. PLYWOOD CORPORATION, ONE CHAMPION PLAZA, STAM Free format text: LICENSE;ASSIGNOR:SECURITY PACIFIC BUSINESS CREDIT INC., A DE CORP;REEL/FRAME:004480/0602 Effective date: 19850828 Owner name: SECURITY PACIFIC BUSINESS CREDIT INC., 10680 TREEN Free format text: SECURITY INTEREST;ASSIGNOR:U.S. PLYWOOD CORPORATION;REEL/FRAME:004480/0584 Effective date: 19850828 |
|
AS | Assignment |
Owner name: U.S. PLYWOOD CORPORATION, CONNECTICUT Free format text: RELEASED BY SECURED PARTY;ASSIGNOR:SECURITY PACIFIC BUSINESS CREDIT INC.;REEL/FRAME:005219/0021 Effective date: 19870828 |