FR3035021B1 - WORKTOP AND METHOD FOR MANUFACTURING THE SAME - Google Patents

Abstract

Worktop panel consisting of a base board (10) of a wood-based composite material whose underside (10a) is covered by a counterbalancing layer (11) and the top (10b) by a layer of The layer (30) formed from a combined sheet (20) is composed of a cover and reinforcement sheet (22) incorporating a decorative sheet (21). The combined sheet (20) is fixed by its decorated side, to the upper face (10b) of the base panel (10) by a phenolic film (12) impregnating the combined sheet (20) and the upper face (10b). ) of the base panel (10).

Description

Field of the invention

The present invention relates to a worktop consisting of a panel made of a wood-based composite material whose underside is covered by a counterbalancing layer and the upper face is provided with a covering and protection layer . State of the art

Currently, the worktops, consist of a base panel whose upper face is provided with a covering elbow formed of a phenolic underlay (underlay) on which is applied a sheet of paper decoration and the assembly coated with a layer of protective coating (overlay); the other side of the panel receives a counterbalancing sheet to balance the constraints. This stack is hot pressed to be secured.

FIG. 5 shows in its portion 5A, the stack of sheets 200 comprising: the base panel 10 with above (10b), the fixing sheet 12 covered by the decor sheet 13 and on top of it, the protective sheet 14, and the underside 10a of the base panel 10 lined with the counterbalancing sheet 11.

Attachment sheet 12 (underlay) is a sheet of heavyweight kraft paper (120-200 grams) impregnated with prepolymerized phenolic resin.

The decorative sheet 13 is a cellulose sheet provided with the decor and impregnated with melamine. This sheet 13 is prepolymerized.

Finally, the protective sheet 14 (overlay) is a very thin sheet of paper of a very low grammage (20.25 grams) impregnated with alumina-loaded melamine Al 2 O 3 constituting an additive reinforcing the wear resistance of this sheet. protection which is also prepolymerized.

The counterbalancing sheet 11 is a sheet of heavyweight kraft paper impregnated with melamine and prepolymerized.

Figure 5B shows the worktop 1 after compression and hot gluing of the stack of sheets 200 in a hot press.

The fixing sheet 12 melts and now impregnates the decor sheet 13; it combines with both the upper face 10b of the base panel 10 and the protective sheet 14 so that the three sheets 12, 13, 14 form a single layer 30 attached to the top 10b of the base panel 10. L The whole is polymerized completely in the hot press and forms the panel which will be cut into a work plan.

The manufacturing method of the working plane 1, known, is shown schematically in FIG. 6. According to this method, the counterbalancing sheet 11 is put in place (PI) on an assembly plane of the assembly station, then place (P2) the base panel 10 and then place (P3) the fixing sheet 12 and (P4) the decor sheet 13 and finally (P5) the protective sheet 14. The stack 200 thus assembled, is transferred in the hot press to be compressed (P6) and get the panel 1 (Figure 5B).

This manufacturing method is relatively long because it is necessary to assemble the different sheets 11, 12, 13, 14 with a large base panel 10 in the assembly station before transferring this stack of sheets 200 in the heat press to compress the assembly and fix the different sheets together by polymerization and the base panel 10. The assembly operation is relatively long because of the large dimensions of the panel 10, rectangular (for example 2 x 5m) and time incomprehensible handling and placement of each of the sheets 11-14. These operations must be done precisely to avoid creases in the superimposition of the leaves.

Then, the pressed panel, large size is cut (P7) into panels of smaller dimensions corresponding to the dimensions of the work planes.

In some cases, the edge of the panel is machined (cut), that is to say a strip of the base panel 10 is removed to leave only the top layer 30 with the decor and then fold this set on the edge of the panel around the upper edge and obtain a panel with a surround that corresponds, for example to a tablet or a furniture top such as a worktop.

Purpose of rinvention

The present invention aims to reduce the manufacturing cost of the worktop panels by simplifying the manufacturing process and reduce the final cost of manufacturing the worktop.

DESCRIPTION AND ADVANTAGES OF THE INVENTION For this purpose, the subject of the invention is a worktop panel composed of a baseboard made of a composite wood material, the underside of which is covered by a counterbalancing layer and the face upper part by a covering and protection layer, this panel being characterized in that the upper face of the base panel is coated with an upper layer formed from a combined sheet composed of a decorative sheet impregnated by the on top of a melamine film charged with alumina particles Al2O3 and whose bottom has a melamine film, the assembly being in the prepolymerized state, the combined sheet being fixed by its inner side, to the upper face from the base panel by a fixing sheet. The invention also relates to a method of manufacturing such a worktop panel characterized in that a hot compress is a set consisting of a counterbalancing sheet, a base panel, a fixing sheet and a sheet combined, composed of a decor sheet impregnated by the top of a melamine film loaded with Al2O3 alumina particles and whose bottom has a melamine film, the assembly being in the prepolymerized state.

By its structure and its manufacturing process the worktop panel is cost-effective compared to the state of the art by reducing the components used in the manufacture of the panel and thus reducing the number of operations. manufacturing. This allows a significant time saving and consequently a significant reduction in the manufacturing cost.

According to another particularly advantageous characteristic, the fixing sheet is a sheet of kraft paper impregnated with phenolic resin.

According to another very advantageous characteristic, the counterbalancing layer consists of a combined sheet joined to the underside of the base panel by a fixing sheet constituted by a sheet of kraft paper impregnated with phenolic resin, the combined sheet being formed of a top-impregnated decor sheet of a melamine film loaded with alumina particles and whose bottom has a melamine film, the assembly being in the prepolymerized state. There is thus a biface or reversible panel making it possible to manufacture two-sided or reversible worktops doubling the choice of decorations or conversely to divide by two the stock of panels used for the production of worktops for the same diversity of choice. of decoration.

According to an advantageous characteristic, according to the method, the combined sheet is produced by making the combined sheet by passing the decor sheet in a melamine bath to impregnate the decor sheet from underneath and form the bottom film, then impregnate the top a melamine film loaded with Al2O3 alumina particles then pass the assembly thus impregnated in a prepolymerization oven to obtain the combined sheet.

According to another advantageous characteristic, the combined sheet is assembled to the upper face of the base panel by means of a fixing sheet consisting of a sheet of kraft paper impregnated with phenolic resin, this combined sheet being prepolymerized.

According to another advantageous characteristic of the process, the assembly is compressed with heat, the counterbalancing sheet consisting of a combined sheet and a fixing sheet made of kraft paper impregnated with phenolic resin.

Thus overall, the invention reduces the cost of manufacturing panels and therefore that of the work planes by reducing the working time or the acceleration of the speed of production. This reduction is particularly significant in the case of a biface panel since this reduction is almost doubled compared to the traditional manufacturing process of a two-sided panel.

The panel thus manufactured remains dimensionally compatible (that is to say in thickness) and in appearance with panels manufactured according to the traditional process with the same decoration. Thus, once manufacture is complete, the panel element according to the invention is distinguished neither from the outside nor in sectional view of a panel element manufactured according to the traditional method.

drawings

The present invention will be described hereinafter in more detail with the aid of the accompanying drawings, in which: FIG. 1 shows in its parts IA, IB a schematic sectional view of a panel according to the invention before the assembly of different layers composing the panel (Figure IA) and after assembly (Figure IB), Figure 2 is a greatly enlarged sectional view of a combined sheet according to the invention, Figure 3 shows in its parts 3A, 3B a schematic sectional view of a variant of the panel according to the invention before the assembly of the various layers composing the panel (Figure 3A) and after assembly (Figure 3B) to achieve a two-sided panel. FIG. 4 is a block diagram of the panel manufacturing method according to the invention, FIG. 5, in its parts 5A, 5B, schematically shows the section of a stack of layers (FIG. 5A) for forming the panel by compression. Figure 6 is a block diagram of the known method of manufacturing panels.

Description of Embodiments of the Invention

The present invention relates to a panel for producing a worktop and its manufacturing method.

According to FIG. 1B, the panel 1 obtained by the method is formed of a base board 10 covered on the top 10B by a covering layer 30 with the decoration, constituting the layer exposed to wear and on the underside 10a by a counterbalancing layer 1Γ balancing the mechanical stresses induced by the covering layer 30 in the base panel 10.

Here as in all the description, the orientation is that of the figures, that is to say that above corresponds to the upper side according to the drawings and the underside, the lower side still according to the drawings. The base panel 10 is a composite panel formed of particles or wood fibers.

To manufacture the panel 1 (Figure IA), the sheets are stacked and the base panel 10 which is a large panel, for example a rectangle of several meters side (2x5 m). The different sheets covering the panel 1 overflow slightly to avoid uncovered surfaces. The overflow of the layers of the finished panel is then trimmed at the end of manufacture.

According to the invention, a counterbalancing sheet 11 is successively placed on the assembly plane of the assembly station, upstream of the hot press, and the base panel 10 is then installed and covered with the sheet. 12 which receives on the top the combined sheet 20.

According to FIG. 2, the combined sheet 20 is a melamine-impregnated decorative sheet 21 forming on its lower face 21a a melamine film and on its upper face 21b, a melamine film 22b loaded with grains of alumina Al 2 O 3 forming the layer protection to resist abrasion and reveal the decor.

The decorative sheet 21 thus impregnated and provided with a film on its two faces is then polymerized to form the combined sheet 20.

The fixing sheet 12 is a sheet of heavyweight kraft paper (150-200 g) impregnated with phenolic resin; the impregnated sheet 12 is prepolymerized.

The counterbalancing sheet 11 is a sheet of heavyweight kraft paper (150-200 g) impregnated with melamine and then prepolymerized.

The manufacture of the combined sheet 20 is made continuously by passing through the various baths of melamine and melamine loaded with grains or Al 2 O 3 alumina powder. Then, after the pre-polymerization, which is also carried out continuously by passing through an oven, the sheets combined with the dimensions of the base panels 10 are cut.

In the assembly station, the stack 100 is made of four sheets (11, 10, 12, 20). This stack 100 is transferred to the hot press to be hot pressed and polymerized to output the panel 1 with a counterbalancing layer 11 on its underside 10 and a top layer 10b formed on its underside 10b. by the indissociable and indistinct assembly of the combined sheet 20 and the fixing sheet 12 which, moreover, fixes the combined sheet 20. The cover layer 30 is thus formed at the upper face 10b of the base panel 10.

In the same way, the counterbalancing sheet 11 forms the counterbalancing layer 1Γ, secured to the lower face 10a of the base panel 10.

The panel 1 obtained can not be distinguished either externally or by a section, of the structure of the panel 1 according to the state of the art shown in FIGS. 5 and 6 so that elements made from such a panel are compatible with elements made with a known panel.

Figure 4 shows very schematically the method of manufacturing panels according to the invention. In a first step E1, the combined sheet 20 is produced by impregnating a decorative sheet 21. This manufacture is done separately and upstream of the manufacture of the panel itself.

The assembly station is fed (E1) with a counterbalancing sheet 11 and then above this sheet is placed (E2) a base panel 10; this assembly receives (E3), on the top 10b of the panel 10, a fixing sheet 12 made of phenolic resin and above it, (E3) is put the combined sheet 20. The assembly 100 of the sheets thus produced is transferred to the hot press to be compressed (E5). At the press outlet, the polymerized panel is transferred to the cutting station to be cut (E6) into worktop elements.

FIGS. 3A, 3B show a variant of panels Γ according to the invention, the top and bottom of which have the same structure so that the panel Γ constitutes a two-sided, reversible panel that can be used for decorating one or the other face, these sets being obviously different.

According to FIG. 3B, the two-sided panel consists of a base panel 10 covered on its two "tops" with a covering layer 30, 30 'which is a wear-resistant covering layer. The two layers 30, 30 'balance each other the mechanical stresses they induce in the base panel 10.

According to FIG. 3A, the panel 1 'is obtained by hot compression and polymerization of a layer stack 100' similar to the stack 100 of FIG. 1A except that the counter balance sheet 11 is replaced here by a sheet composite 20a covered (in the orientation of Figure 3A) by a fixing sheet 12a.

The composite sheet 20a is of the same structure as the composite sheet 20 covering the "top" but in the inverted position so that its layer 22b 'is turned outwards.

The fixing sheet 12a is identical to the fixing sheet 12. The decorative sheet integrated in the combined sheet 20a has a decoration different from the decoration of the combined sheet 20.

The manufacturing method is the same as that described above with the aid of FIG. 4 except that in step E1 the combined sheet 20a, turned over, which is covered with the 12a fixing and then continues with the E2 step of placing the base panel 10 and so on.

NOMENCLATURE I Finished panel 1 'Finished two-sided panel 10 Base panel 10a Bottom side 10b Upper face II Counterbalancing sheet 11' Counterbalancing layer 12, 12a Fixing sheet forming an underlay 13 Decorating sheet 14 Coating and protection sheet 20, 20a Combination sheet 21 Decorating sheet 21a Below 21b Top 22a Melamine film 22b Alumina particle-laden melamine film AI2O3 Coating and protecting layer 100, 100 'Stacking sheets according to the invention 200 Stacking sheets according to the state of the art E1-E6 Stages of the process of the invention P1-P7 Stages of the known process

Claims (5)

CLAIMS 1 °) Worktop panel composed of a base panel made of a wood-based composite material whose underside is covered by a counterbalancing layer and the upper face by a protective covering layer, panel characterized in that the upper face (10b) of the base panel (10) is coated with a covering and protection layer (30) formed from a combined sheet (20) composed of a decorative sheet ( 21) impregnated by the top (21b) of a melamine film (22b) charged with alumina particles Al2O3 and whose bottom (21a) has a melamine film (22a), the whole being in the prepolymerized state the combined sheet (20) being fixed to the upper face (10b) of the base panel (10) by a fixing sheet (12). 2 °) Worktop panel according to claim 1, characterized in that the fixing sheet (12) is a kraft paper sheet impregnated with phenolic resin. Worktop panel according to claim 1, characterized in that the counterbalancing layer (11) consists of a combined sheet (20a) assembled to the underside (10a) of the base panel (10) by a fixing sheet (12a) consisting of a sheet of kraft paper impregnated with phenolic resin. 4) Method for manufacturing a worktop panel, characterized in that a set (100) consisting of a counterbalancing sheet (11), a base panel (10), a sheet of fastener (12) and a combined sheet (20), composed of a top-impregnated decor sheet of a melamine film loaded with Al2O3 alumina particles and whose underside has a melamine film, the assembly being in the prepolymerized state. Process according to Claim 4, characterized in that the combined sheet (20, 20a) is produced by passing the decorative sheet (21) in a melamine bath to impregnate the decor sheet from underneath ( 21a) and forming the bottom film (22a), - the top (21b) is impregnated with a melamine film (22b) charged with alumina particles Al2O3 - then the assembly thus impregnated is passed through an oven of prepolymerization to obtain the combined sheet (20, 20a) 6 °) Method according to claim 4, characterized in that the combined sheet (20) is assembled to the upper face (10b) of the base panel (10) by the intermediate of a fixing sheet (12) consisting of a sheet of kraft paper impregnated with phenolic resin. 7 °) Method according to claim 4, characterized in that hot compressing the assembly (100), the counterbalancing sheet (11) is constituted by a combined sheet (20a) and a fixing sheet (12a) formed of kraft paper impregnated with phenolic resin.