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Embossed-in-register manufacturing process
| Details |
Inventors: Cruz, Eugenio;
Assignee: Industrias Auxiliares Faus S.L. (Gandia, ES)
Primary Examiner: Aftergut; Jeff H.
Assistant Examiner: Rossi; Jessica
Attorney, Agent or Firm: McKenna Long & Aldridge LLP
A method of producing embossed-in-register building products. Reference edges are milled on a board. A resin soaked paper having a decorative motif is located on that board using the reference edges as a guide such that the decorative motif has a predetermined position relative to the reference edges. The board and paper are then located in a press machine having a press plate with a three dimensional surface that is registered with the decorative motif. The press plate presses into the board and paper at a predetermined pressure and predetermined temperature to set the resin, producing a final product. Resin and paper parameters are carefully controlled. The press plate is manufactured such that the plate's surface registers with the decorative motif when the press plate is hot. Appropriate hollowing and milling of the board can even out pressure distributions and to provide a completely closed surface without porosity. |
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DETAILED DESCRIPTION The principles of the present invention provide for a method of fabricating alternative building and finishing materials that have decorative motifs and surface textures that are mechanically embossed in registration with the decorative motifs.
A method according to the principles of the present invention includes milling a reference edge on a board, and then locating a resin soaked paper having a decorative motif on that board using the reference edge such that the decorative motif has a predetermined position relative to the reference edge.
Beneficially, the paper is adhered to the board using static electricity.
The board and paper are then moved into a press machine and accurately positioned within the press machine, using the reference edge as a guide, such that the decorative motif assumes a predetermined position relative to a press plate having a predetermined temperature.
The press machine is closed, and the hot press plate presses the paper into the board with a predetermined force for a predetermined period of time.
Beneficially, the resin and paper are carefully controlled as to dimensions and material composition.
Beneficially, the paper is manufactured by one supplier, on one machine, using materials from the same supplier, and with careful attention to cellulose materials, spool winding directions and spool winding tensions.
Beneficially, the resin is manufactured by one supplier, using one reaction vessel, using materials from the same source, and with careful attention to material mixing and solid content.
The press plate, which has a three-dimensional surface, is beneficially manufactured such that the press plate surface matches the decorative motif when the press plate is heated to its operating temperature.
In practice it is generally better to use a slow curing resin and lower press operating temperatures then in the prior art.
This improves the quality of the final surface.
If the surface texture has a roughness sufficient to significantly disturb the pressure distribution across the paper and board during embossing, the board can be appropriately hollowed prior to embossing to even out the pressure distribution
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Optical Systems 
