US3764645A - Method of molding coated articles of fibrous materials - Google Patents

Method of molding coated articles of fibrous materials Download PDF

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Publication number
US3764645A
US3764645A US00139535A US3764645DA US3764645A US 3764645 A US3764645 A US 3764645A US 00139535 A US00139535 A US 00139535A US 3764645D A US3764645D A US 3764645DA US 3764645 A US3764645 A US 3764645A
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United States
Prior art keywords
recesses
corner
impressed
conical
bottom face
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Expired - Lifetime
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US00139535A
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English (en)
Inventor
E Munk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Furnier und Sperrholzwerk JF Werz Jr KG Werzalit Pressholzwerk
Original Assignee
Furnier und Sperrholzwerk JF Werz Jr KG Werzalit Pressholzwerk
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N5/00—Manufacture of non-flat articles

Definitions

  • the present invention relates to a method of producing molded articles which may have planar or uneven surfaces and angular, rounded or specially-shaped projecting edges and are made by application of heat and pressure to a mixture of comminuted organic fibrous materials, for example, wood chips, with a hot-setting binder and are coated with a thin decorative sheet material.
  • the invention relates to improvements in the method as disclosed by the present applicant in the patent granted in the Federal Republic of Germany, No. 1,255,300, and also in corresponding patents granted in numerous other countries.
  • a blank of substantially the same shape as, but a slightly larger size than the finally molded article is first produced by cold-molding, and in a subsequent hot-molding operation this blank is further compressed to its final shape and size, the coating material is molded thereon, and the binder is set completely.
  • the known method as disclosed in the mentioned German patent provides that the die for molding the normally lower side of the article is provided with projecting ridges for impressing continuous or interrupted grooves into the molding material which preferably extend parallel to and at a short distance from the edges of the molded body or from one or more projections on the other side of the body. These grooves are usually impressed during the hot-molding operation, although they may also be partly premolded in the cold-molded blank.
  • These projecting ridges on the die are designed so that by molding the grooves they cause an additional compression of the material near the edges of the molded body and, if desired, also near a projection on the normal plane of this body, and thereby prevent any substantial shrinkage of the molding material while it is setting, especially with respect to the covering-sheet material, by insuring that the back pressure'which has to be exerted upon the outer surface of the sheet material to bond the same to the molded body will be suffi-, cient at all points and especially near the edges and projections of the body.
  • the ridges on the die also have the function of gripping the material while it is setting so that also for this reason no substantial shrinking can occur.
  • the surface of the die is provided with at least a pair of projecting ridges which extend, for example, at right angles to each other, but if for reasons of a more simple manufacture these ridges are not made of such a length that their adjacent ends join each other and form an apex so that the molded body would then be provided with a continuous rectangular groove which extends parallel to two adjacent edges of the body and the apex of which is located adjacent to the rectangular corner between these edges.
  • this corner area which, as has now been found, should actually be more highly compressed than the other marginal areas will be devoid of any additional pressure and will thus be subject to shrinkage, and the covering layer will therefore be bonded insufficiently to this corner area.
  • SUMMARY OF THE INVENTlON lt is an object of the present invention to overcome these disadvantages of the method as previously described and to insure that, by impressing recesses from the bottom face, and especially at the corner areas of a molded article which is covered with a thin sheet material, the material within these areas will be so highly compressed during the final hot-molding and bonding of the sheet to the compressed material that a sufficient back pressure will also be exerted at these areas so that the sheet material will be securely bonded thereto.
  • all of these recesses may be impressed to a greater depth than that to which the v groovelike recesses could be impressed by the known method without danger that the covering sheet material might be deformed or marked on its outer surface.
  • the present invention provides especially each corner area of the die with a conical or similar projection so as to impress a recess of a corresponding shape from the bottom face of the molded article into the latter at a point which is located 1 on the bisecting line of the angle which is formed by each of the angular or rounded corners of the article.
  • conical corner recesses may be provided in combination with groovelike recesses of the type, in accordance with the known method, which preferably extend parallel and adjacent to side faces of the molded body and may either terminate closely adjacent to the conical corner recess which is made of a greater depth than the groovelike recesses or extend into the lower part of the conical corner recess. Since such a conical recess may be safely made of a considerably greater depth than the adjacent groovelike recesses, the comer area of the molded article will be more highly compressed in accordance with the invention than the adjacent marginal parts so that the necessary pressure will also be produced within the angular or rounded corner area to secure the thin sheet material at all points firmly to the upper, lower and lateral faces of the corner area,
  • the pressure components will be distributed within the article in such a manner that the covering layer will not be deformed or marked on its outer side even though the depth of the recess from its free outer end to its point-like inner end is made much larger than the depth of one of the groovelike recesses.
  • the angle of the taper of each conical projection on the die, and especially of each corner projection is made of such a size that the base diameter of this projection which corresponds to and produces the maximum diameter of the conical recess at the free end thereof is considerably larger than the width of the base of one of the ridgelike projections for molding one of the groovelike recesses. This is true especially when a conical corner recess is employed in combination with two adjacent groovelike recesses which extend parallel to the adjacent edges of the molded article, and it is also true regardless of whether the ends of these groovelike recesses are spaced at short distances from the free outer end of the conical corner recess or whether they terminate in the free outer end of the corner recess.
  • This has the advantage that due to their shape the conical recesses forming such a row may also be made of a considerably greater depth and a greater width at their outer ends than the groovelike recesses.
  • Such rows of conical recesses may be employed in combination with conical corner recesses by extending substantially parallel to the adjacent edges of the molded article, in which event, however, the conical corner recesses should preferably be made of a greater depth and a greater maximum diameter than those of the adjacent rows.
  • Such a row of rows of recesses may, however, also be impressed into one side of the article to compress the same more highly atanother area or other areas which are provided with a projection or projections on the opposite side of the article.
  • the adjacent conical recesses of such a row may also merge into each other at their larger outer ends, and if employed in combination with larger conical corner recesses, the smaller conical recesses next to such a corner recess may also merge partly into the free end of the larger corner recess.
  • the recesses according to the invention as well as the die projections for producing these recesses are described as being of a conical shape tapering to a point, they may also be of another tapering shape, for example, of the shape of a pyramid with three or more sides. It is also not absolutely necessary that they taper to a point, but they may also terminate in a small rounded inner end or in a small flat surface.
  • FIG. 1 shows a bottom view of a corner part of a plate which is produced in accordance with the invention
  • FIG. 2 shows a cross section which is taken along line II-II of FIG. 1, and in which, for better illustration, the covering layer is shown of a thickness considerably greater than its actual thickness;
  • FIG. 2a shows a partial cross sectional view of a die for forming the plate partially shown in FIGS. 1 and 2;
  • FIG. 3 shows a bottom view of a corner part of a plate according to a modification of the invention
  • FIG. 4 shows a bottom view of a corner part of a plate according to a further modification of the invention.
  • FIGS. 1 and 2 of the drawings illustrate one corner part of a plate 3 which is produced in accordance with the present invention.
  • Plate 3 is provided with groovelike recesses 6 which are impressed into the lower side of the plate and each of which extends substantially parallel to and at a certain distance from the adjacent outer edge up to a point near each corner of the plate.
  • Each of these corner parts of plate 3 is provided with a conical recess 7 which is separate from the adjacent grooves 6 and has at its outer end a maximum diameter dwhich is larger than the maximum width b of the outer side of the grooves 6.
  • the body of plate 3 which is molded from a mixture of comminuted fibrous materials, for example, wood chips, and a thermosetting binder in the form of a natural or synthetic resin, is covered on all sides,,with the exception of the deeper inner surfaces of the conical recess 7, and possibly also of the bottom of grooves 6, with a continuous layer 4 and 5 of a suitable sheet material which is bonded together with the body of plate 3 by the hot-molding operation.
  • FIG. 2 illustrates the higher rate of compression V which is attained within the corner area of plate 3 by impressing the conical recess 7 into its lower side to a depth T which is considerably deeper than the depth 1 of the adjacent grooves 6.
  • the lower-mold part D is provided with ridges 6' projecting upwardly from the upper surface of the lowermold part, and are inwardly spaced from and substantially parallel to the side faces thereof which define the mold cavity C.
  • the ridges 6 and the conical projections 7 will penetrate into the bottom face of the blank to provide the latter with groovelike recesses 6 and conical recesses 7 as described above.
  • the comminuted fibrous material is more highly compressed in the region of the ridges 6, and especially in the region of the conical projections 7', which have, as shown in FIG. 2a, a height greater than that of the ridges.
  • This greater compression of the blank in the region of the ridges and the conical projections will prevent shrinking of the plate during setting of the molding mixture in the final hot molding operation, especially since the aforementioned ridges and projections will penetrate during such molding operation into the recesses formed thereby.
  • This in turn, will assure proper bonding of the outer sheet to the body of the plate 3 during the hot molding operation since any relative shifting of the adjacent surfaces of the outer sheet and the body of the plate during the final hot molding operation is thus prevented.
  • FIG. 3 shows a bottom view of a corner part ofa plate 3 which is provided with groovelike recesses 6 and deeper conical corner recesses 7 according to a modification of the invention.
  • the mold for producing the plate shown in part in FIG. 3 is similar to the mold described above in connection with FIG. 20, but differs therefrom in that, in this case, the ridges in the bottom part of the two-part mold extend up to and are joined to the conical projection provided at each comer.
  • FIG. 4 shows a bottom view of a corner part of another plate 3 into the lower side of which two rows of conical recesses 8, which extend substantially parallel to the adjacent edges of plate 3, are impressed in place of the grooves 6 as shown in FIGS. 1 and 2.
  • the conical corner recesses 7 are preferably made deeper than the recesses 8 adjacent to the lateral edges of plate 3, the diameters of the outer ends of the corner recesses 7 are preferably also made larger than those of the recesses 8 of the lateral rows.
  • the diameters of the outer ends and/or the depths of all of the conical recesses 7 and 8 may also be made of the same size or sizes.
  • the mold for producing the plate partly shown in FIG. 4 is similar to the mold described above in connection with FIG. 2a but, instead of longitudinal ridges 6, there are provided rows of substantially conical projections for forming the recesses 8 which have, however, a smaller maximum diameter and a shorter height than the corner projections for forming the recesses 7 at each comer of the plate.
  • the recesses 7 or 8 may also be made of a tapering shape other than conical, for example, of a pyramidal shape with three or more sides. In such an event, it may be of advantage to make the different sides of each pyramid of different inclinations relative to the plane surfaces of the upper and lower sides of plate 3, for example, by making the sides of the pyramids facing the outer edges and corners of the plate of a steeper inclination than the inwardly facing sides.
  • the recesses 7 or 8 are made of a conical shape, their axes may be similarly inclined toward the corners or toward the lateral edges of plate 3.
  • thermosetting binder maintaining the thus compressed and impressed element in compressed condition at least until said activated thermosetting binder has set so as to bond said fibrous material and said cover sheet thereto and to prevent shrinkage of said element in said corner regions thereof during said setting of said thermosetting binder.
  • each of said corner recesses has a conical shape.
  • each of said corner recesses has a pyramidal shape having at least three sides.
  • each of said corner recesses is impressed into said element so as to have at said bottom face adimension'greater than the width of said recess means at said bottom face.
  • each of grooves are impressed in such a manner that they inter- 5 sad conseiutwe recesses has a conical p sect said corner recesses.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
US00139535A 1968-05-02 1971-05-03 Method of molding coated articles of fibrous materials Expired - Lifetime US3764645A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE1703323A DE1703323C3 (de) 1968-05-02 1968-05-02 Verfahren zur Herstellung und Beschichtung profilierter Spanpreßteile

Publications (1)

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US3764645A true US3764645A (en) 1973-10-09

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US00139535A Expired - Lifetime US3764645A (en) 1968-05-02 1971-05-03 Method of molding coated articles of fibrous materials

Country Status (5)

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US (1) US3764645A (es)
DE (1) DE1703323C3 (es)
ES (1) ES366678A2 (es)
FR (1) FR2007632A6 (es)
GB (1) GB1256115A (es)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4153490A (en) * 1977-05-05 1979-05-08 Werzalit, J. F. Werz Jr. Kg Pressholzwerk Method of manufacturing coated composite articles from a non-flowable mixture, and articles obtained thereby
US6243931B1 (en) 1998-09-15 2001-06-12 Batesville Services, Inc. Casket lid and method and making same
US6511567B1 (en) 1999-03-31 2003-01-28 International Paper Company Composite building components and method of making same
US6773791B1 (en) 1999-03-31 2004-08-10 Masonite Corporation Composite building components, and method of making same
US20040244163A1 (en) * 1998-09-15 2004-12-09 Batesville Services, Inc. Casket lid and method of making same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE9114920U1 (de) * 1991-12-02 1993-02-04 Dreer, Franz, 86825 Bad Wörishofen Platte mit Postformingkante

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1255300B (de) * 1965-08-12 1967-11-30 Werz Furnier Sperrholz Verfahren zur Herstellung und Beschichtung profilierter Spanpressteile
US3373233A (en) * 1964-03-30 1968-03-12 Plexowood Inc Method of molding countertops
US3439081A (en) * 1966-01-13 1969-04-15 Pag Presswerk Ag Method of molding a material to prevent plugging of vent holes in the die

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR969140A (fr) * 1947-07-15 1950-12-14 Ji Te Ab Perfectionnements à la fabrication de plaques à partir de pièces de matière cellulosique et plaques conformes à celles ainsi fabriquées

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3373233A (en) * 1964-03-30 1968-03-12 Plexowood Inc Method of molding countertops
DE1255300B (de) * 1965-08-12 1967-11-30 Werz Furnier Sperrholz Verfahren zur Herstellung und Beschichtung profilierter Spanpressteile
US3439081A (en) * 1966-01-13 1969-04-15 Pag Presswerk Ag Method of molding a material to prevent plugging of vent holes in the die

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4153490A (en) * 1977-05-05 1979-05-08 Werzalit, J. F. Werz Jr. Kg Pressholzwerk Method of manufacturing coated composite articles from a non-flowable mixture, and articles obtained thereby
US6243931B1 (en) 1998-09-15 2001-06-12 Batesville Services, Inc. Casket lid and method and making same
US6503429B1 (en) 1998-09-15 2003-01-07 Batesville Services, Inc. Casket lid and method of making same
US20040244163A1 (en) * 1998-09-15 2004-12-09 Batesville Services, Inc. Casket lid and method of making same
US6849141B2 (en) 1998-09-15 2005-02-01 Batesville Services, Inc. Casket lid and method of making same
US6922877B2 (en) 1998-09-15 2005-08-02 Batesville Services, Inc. Casket lid and method of making same
US7147811B2 (en) 1998-09-15 2006-12-12 Batesville Services, Inc. Casket lid and method of making same
US7247264B2 (en) 1998-09-15 2007-07-24 Batesville Services, Inc. Casket lid and method of making same
US6511567B1 (en) 1999-03-31 2003-01-28 International Paper Company Composite building components and method of making same
US6773791B1 (en) 1999-03-31 2004-08-10 Masonite Corporation Composite building components, and method of making same

Also Published As

Publication number Publication date
DE1703323A1 (de) 1972-01-27
DE1703323B2 (de) 1977-07-14
FR2007632A6 (es) 1970-01-09
DE1703323C3 (de) 1978-03-09
ES366678A2 (es) 1971-04-16
GB1256115A (en) 1971-12-08

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