PVC FOIL LAMINATION MACHINE WITH GRADUAL VACUUM AND DYNAMIC THERMAL DAMPING FOR WOODEN PANEL AND DOOR SURFACES.

Abstract

The invention relates to a lamination machine and lamination method that enables the continuous lamination of PVC and similar thermoplastic foils onto grooved, jointed, and patterned wooden panel surfaces using hot melt adhesive (PUR hotmelt) in the manufacture of furniture, doors, and wooden structural elements. The invention essentially consists of a coarse brush module (A1) and a wet brush module (A2) that clean coarse particles and static dust from the surface of the wooden panel, a preheating group (B) with a heating group (B) that brings the panels to the reaction temperature, a movable nozzle jaw group (C) that applies glue, a shaft and glue roller module (D) that provides foil feeding, a vacuum group (E) that performs the vacuuming process, and a protective tape module (F) that provides surface protection.

Description

1 TARIFF GRADUAL VACUUM AND DYNAMIC SEALING FOR WOOD PANEL AND DOOR SURFACES. HEAT-DAMPENED PVC FOIL LAMINATION MACHINE 5 Technological Field: The invention is used in the furniture, door and wood structural element manufacturing industry; 10 with profile surfaces that are hollow, patterned, channeled or of varying depths. PVC and similar materials for wood panel, MDF, particle board and door surfaces. seamless bonding of thermoplastic foils via hot melt adhesive (PUR hotmelt) (continue) with a lamination machine that enables lamination on the line. It is related. The invention describes variations in foil tension and thickness during adhesive application. a damping adhesive release and braking module, vacuum along the line an asymmetric grooved and synchronously driven panel transmission that prevents losses a multi-stage vacuum system that can be adjusted according to the mechanism and panel width This relates to a PVC foil lamination machine that has a hopper. State of the Art: In the furniture, door, and wood structural elements industry; MDF, particle board, or The surfaces of solid wood-based panels are designed to provide an aesthetic appearance and resist moisture. and to provide protection against external factors, PVC, PP or similar 25 They are laminated with synthetic foils. The panels have a completely flat surface. While classic roller lamination methods are sufficient; for deep joints, bay windows Detailed, rustic patterned panels and doors with full-length cutouts to ensure the foil adheres perfectly to all the details of the wood on the surfaces. Vacuum-assisted lamination machines are used. 30 2 Traditional vacuum lamination machines and industry standard. In the solutions used, glue application to the foil is usually done directly through the slot nozzle. This is accomplished via (jaw) units or standard roller groups. However In these structures, as the foil is unrolled from the roll and even progresses, the surface tension and the foil's elasticity change. There are momentary fluctuations in thickness at the micron level. Slot 5 Mechanical damping between the nozzle jaw and the flexible foil. Because these tension differences are not present, the adhesive adheres homogeneously to the foil surface. It prevents it from spreading. As a result, the glue grammage along the bonding line. deviations, glue deposits, surface streak formation, and after coating Visual imperfections called "orange peeling" or "pimples" appear. 10 It is emerging. Another critical technical problem is hot melt (PUR) application. These are the cleaning and maintenance processes of the units. In known systems, slot nozzles... The modules are fixed to the machine body and main chassis. Production 15 reagents that accumulate in the nozzle jaws during breaks or changes in adhesive type Cleaning the glue is extremely difficult. The operator is in a confined space inside the machine. and has to interact with parts that are at high temperatures. This situation creates both a workplace safety risk and requires careful handling during cleaning. This leads to nozzle adjustment problems, significantly increasing downtime. It increases. During the transmission and vacuum phase, current technologies drive the panels from below. It is based on the principle of moving the vehicle along a continuous line over rollers. However, in conventional flat or standard rubber-coated drive rollers, 25 Axial displacement or speed of wooden panels when passing under vacuum due to the difference, millimeter-sized gaps (openings) form between the two panels. This is a common occurrence. These gaps that form between the panels create a vacuum. This causes significant air leaks (vacuum drop) in the area. The vacuum power The sudden fall caused the foil to fall into the deep grooves on the wooden panel and 30 the patterns may not be fully drawn into the fabric, resulting in air bubbles, or This leads to the coating remaining weak. 3 In addition, the vacuum chambers are adjusted according to the panel width. Existing mechanical solutions used (narrowing rooms or numerous deflections) (systems including valves) can become clogged with glue dust and wood chips over time. It is jamming or the seal is losing its watertightness. The width of the panels is 5 Precisely and leak-proofly adjusting the width of the vacuum channel as it changes. This is becoming more difficult, leading to inefficient energy use and inconsistent lamination. This is what causes its quality. In addition, the wood panel, heated and stretched by the vacuum effect, has a depth of 10 The adhesion quality of the PVC foil applied to the grooves depends on the reactivity of the adhesive and the environment. It is directly related to the conditions. The rapid exit of products from the vacuum zone In conventional systems where cooling is not possible, the internal structure of the foil... It tends to stretch back due to stresses (memory effect). The glue is not yet... This springback, occurring before complete ossification, is particularly noticeable in patterned and deeply jointed 15 This causes the foil to peel off (jump / bubble) in some areas. is happening. Purpose of the Invention: The primary purpose of the invention is to create hollow, jointed, and patterned wooden panels or doors. During the lamination of PVC foil to surfaces, a thickness increase occurs in the adhesive film. A lamination that completely eliminates distortions and surface defects. The goal is to develop a machine for unwinding the foil from the roll. In traditional systems, the foil is unwound from the roll. The momentary tension and thickness fluctuations that occur during this process, slot 25 This leads to uneven accumulation of glue in layers at the nozzle outlet and on the surface. This leads to the formation of a line. The invention integrates the slot nozzle module in front of it. silicone glue, whose rotational resistance is controlled by a braking module. Thanks to the combination of the roller and the shock-absorbing support on the jaw, Tension differences in the foil are mechanically damped. Thus, the foil 30 The amount of hot melt adhesive (PUR hotmelt) applied to the surface is constant at the micron level. By treating these issues, orange peel skin, acne, and fine lines are prevented. 4 Another purpose of the invention is to improve the cleaning, maintenance, and operation of hot melt adhesive application units. The goal is to minimize machine downtime by streamlining service processes. In conventional machines, slot nozzles are fixed to the machine chassis. The jaws present significant challenges for the operator during the cleaning of reactive glue, and 5 This creates occupational safety risks. The invention includes a slot nozzle module. on an independent movable table that moves on linear slides It is positioned in a way that, thanks to this mechanical design, the jaw group can be used for hot cleaning or sensitive machine and setting parameters remain undisturbed during maintenance procedures. It can be pulled axially outside the machine body, safely and for the last 10 days. A very fast cleaning service is offered. Another critical objective of the invention is the transmission of wood along a continuous line. Eliminating gaps between products and vacuuming by preventing panels from sliding. The goal is to completely prevent air leaks in the area. Current technologies have 15 Axial displacements in standard drive rollers create gaps between panels. and consequently causes momentary drops in suction in the vacuum chamber. In the invention, the driving rollers that contact the underside of the wooden panels are asymmetrical. Designed with a grooved structure, the entire drive mechanism is a single helical gear motor. They are driven synchronously via a gearbox. Thus, the panels 20 It moves linearly and without slippage along the line, with gaps between products. By eliminating impurities, a constant and high suction power is obtained in the vacuum region. Another purpose of the invention is to create a vacuum according to the width of the wooden panel to be processed. 25 The aim is to provide complex valve mechanisms or traditional systems. Shrinking chambers, due to dust and glue residue, can become clogged and leak over time. This causes problems. The invention concerns a lamination machine with a vacuum submersible system. It has an internal trapezoidal shaft placed inside its housing and special sealing gaskets. The vacuum channel is 30 according to panels of different widths via side adjustment blocks. It can be confined precisely and leak-proof without the risk of pinching. Finally, one of the aims of the invention is to heat the wood during the vacuuming process. The PVC foil stretches back when stretched into the deep grooves and patterned areas of the panel. The purpose is to prevent this and to solidify the adhesion quality by sealing it. Vacuum air conditioning hood cooling unit integrated into the outlet of the area with foil and The adhesive layer is rapidly subjected to thermal shock immediately after vacuuming, 5 It is being fixed. Explaining the Figures: The invention will be described by reference to the attached figures, so that the invention is defined as 10 Its features will be understood more clearly. However, the purpose of this invention is not this specific one. It is not about limiting it with regulations. On the contrary, the invention's accompanying claims all alternatives and modifications that can be included within the area defined by it and the inclusion of their equivalencies is also intended. The details shown are only It is shown for the purpose of describing the preferred arrangements of the present invention and 15 both the shaping of methods and the rules and concepts of invention to provide the most useful and easily understandable description of its properties It should be understood that they are presented in these drawings; Figure 1 shows a perspective view of the coarse brush module and the wet brush module. 20 Figure 2 shows the exploded detail view of the coarse brush module and the wet brush module. Figure 3 shows the front view of the coarse brush module and the wet brush module. Figure 4 shows a perspective view of the preheating unit. Figure 5 - Jaw Module, Movable Table Module and Jaw Position Adjustment Module It is a perspective view. 25 Figure 6 shows the perspective and detail view of the shock absorber module. Figure 7 shows the front view of the jaw position adjustment module. Figure 8 shows the front view of the foil shaft assembly. Figure 9 is a detailed perspective view of the glue roller and pneumatic piston. Figure – 10 Printing module, vacuum module and main motion motor top 30 It is the appearance. Figure 11 shows the top view of the vacuum heater unit. 6 Figure 12 – Top view of the main drive motor assembly. Figure 13 – Cross-sectional view of the printing module and vacuum top plate. Figure 14 - Perspective view of the motion transmission gearbox. Figure 15 - Top view of the vacuum module. Figure 16 – Perspective view of the vacuum group. 5 Figure 17 – Perspective and side view of the protective tape module group. Figure 18 – Perspective view of the complete assembly of the machine that is the subject of the invention. Illustrations that will help understand this invention are shown in the attached image. They are numbered and their names are given below. 10 Explanation of References: A1. Coarse brush module A1-1. Coarse brush 15 A1-2. Coarse brush motor A1-3. Coarse brush hood. A1-4. Coarse brush printing group A1-5. Coarse brush air comb module A1-6. Coarse brush movement module 20 A2. Wet brush module A2-1. Wet brush motor A2-2. Water brush spray valve A2-3. Wet brush 25 A2-4. Wet brush motion module A2-5. Wet brush hood. B. Preheating group B1. Sigma chassis group 30 7 B2. Heating unit B3. Heater Sockets B4. Heater adjustment plate C. Movable Jaw Group 5 C1. Jaw Module C2. Movable Table Module C3. Jaw position adjustment module C4. Shock absorber module C5. Jaw double hose inlet 10 D. Shaft and Glue Roller Module D1. Foil Shaft D2. Shaft Brake Assembly D3. Shaft Movement Motor 15 D4. Shaft Module Manual Movement D5. Fixed Adjustment Roller D6. Movable Adjustment Roller D7. Pneumatic Piston D8. Glue Roller Brake 20 D9. Glue Roller D10. Glue heater D11. Silicone Top Print D12. Edition Manual Adjustment D13. Silicone Substrate Printing 25 E. Vacuum Group E1. Printing Module 8 E2. Vacuum Module E3. Main Drive Motor E4. Motion Transmission Gearbox E5. Vacuum Motor E6. Vacuum Base Plate 5 E7. Vacuum Adjustment Trapezoidal Group E8. Vacuum top plate E9. Air Conditioner Hood Group E10. Vacuum Heater Unit E11. Vacuum Hose Inlet 10 E12. Vacuum Inner Seal Assembly F. Protective Tape Module F1. Protective Band Shaft F2. Protective Band Brake Assembly 15 F3. Protective Band Fixed Shaft F4. Protective Band Adjustable Roller, Description of the Invention: The subject of the invention is PVC foil with stepped vacuum and dynamic thermal damping. Wooden panels or door surfaces entering the lamination machine are first... wood dust, burrs and coarse particles found on the upper surface of the panels It is sent to the coarse brush module (A1) for cleaning. Here, the coarse brush The coarse brush (A1-1) surface is mechanically 25 driven by the motor (A1-2). When sweeping, the resulting dust is sucked up by means of the coarse brush hood (A1-3). Positioning the coarse brush according to the panel height and thickness tolerances. This is provided by the pressure group (A1-4) and the coarse brush movement module (A1-6); to the surface Adhered static dust can be removed via the coarse brush air comb module (A1-5). It is lifted with blown compressed air. The wooden panel, after rough cleaning is completed, is 30 9 Immediately afterwards, it enters the wet brush module (A2). In this module, wet brush The special solution sprayed through the spray valve (A2-2) moistens the surface, aqueous. The rotating wet brush (A2-3) with brush motor (A2-1) picks up fine micronized powders. Holding it, transfer the water towards the brush hood (A2-5). The system height is determined by the water brush. 5 for laminating wood panel surfaces by adjusting with the movement module (A2-4). It is brought to a perfect level of cleanliness. The cleaned wooden panel is then prepared for lamination. heating the surface causes the hotmelt glue to cool and react prematurely. To prevent it from entering, it is transmitted to the preheating group (B). This module is machine 10 It is rigidly integrated into the chassis architecture with the Sigma chassis group (B1). Wood Homogeneous and directed thermal energy transfer to the panel surface heating group (B2) This is done via electrical connections of heating elements and heater sockets. While securely provided via (B3), the panel's transition height and Heat distribution according to regional focus needs is achieved via the heater adjustment plate (B4) 15 It is mechanically guided with precision. As the preheated wooden panel line moves towards the lamination area, PVC foil feeding and adhesive application are carried out. The foil is taken from the roll. Unwinding is achieved via the foil shaft (D1); oscillations depending on line speed and 20 Tension differences shaft brake assembly (D2), shaft drive motor (D3) and shaft module It is kept under control by manual movement (D4). The foil is fixed by the adjustment roller (D5). and passed over the movable adjustment roller (D6) to the glue application area is directed. Hot glue is applied from the jaw dual hose inlet (C5) to the nozzle jaw module (C1) It is fed. Deviations in thickness and tension in the foil during glue application, The nozzle jaw module (C1) is mechanically integrated with the shock absorber module (C4). It is damped as follows. Glue transfer is positioned by a pneumatic piston (D7). This is done via the glue roller (D9). The 30 on the glue roller (D9) The viscosity of the glue is maintained by the heater (D10), while the rotational speed and resistance of the roller are controlled. The glue roller brake (D8) is precisely controlled. This entire jaw assembly, It is mounted on the movable table module (C2) which operates on linear slides; Position adjustment during production thanks to the jaw position adjustment module (C3). During the process, the entire jaw assembly of the machine chassis is checked during maintenance and cleaning. It can be pulled outwards axially. The PVC foil and wooden panel, after the adhesive application is complete, are applied to the joints and grooves. To ensure the foil adheres perfectly, it is sent to the vacuum group (E). This is done. Uninterrupted transmission of panels on the line and the gap between them reset, main drive motor (E3) and its associated drive gearbox 10 with silicon underprint roller (D13) synchronously driven via (E4). This is provided. Top printing and forming operations are performed using manual printing settings. silicone top pressure roller (D11) positioned with mechanism (D12) and It is executed via the printing module (E1). The panel is enclosed in a 15-inch space between the vacuum bottom plate (E6) and the vacuum top plate (E8). When it enters the vacuum area, the suction generated by the vacuum motor (E5), The foil is transferred to the area via the vacuum hose inlet (E11) and applied to the entire panel. The details are captured. Temperature balance in a vacuum environment It is protected by a heating element (E10). Vacuum is applied according to the width of the panel to be processed. The area is sealed and confined, with a vacuum setting of 20 working inside the chamber. trapezoidal group (E7) and vacuum internal seal group (E12) integrated with this group is carried out. The panel, which comes out of the vacuuming area and has the foil attached, To prevent stretching back in patterned areas and to prevent glue ossification 25 air applied through the air conditioning hood assembly (E9) in order to accelerate It is instantly cooled and frozen by the current. The panel moves to the end of the line. Protective tape to prevent scratching and protect against external factors. The module (F) is entered. Here, the protective film is passed through the protective tape shaft (F1). The protective band is opened by being fed into the brake assembly (F2) control; protective band 30 laminated via a fixed shaft (F3) and a protective band adjustable roller (F4) The process is completed by applying it to the surface. 11 The subject of the invention is PVC foil with stepped vacuum and dynamic thermal damping. The lamination method performed on the lamination machine is basically as follows: The process includes the following steps: a) Wood Panel Surface Cleaning: Cleaning the surface of the wood panel to be processed. mechanical coarse particles and static dust in coarse brush module (A1) Removal by sweeping and air blowing, then in the wet brush module. (A2) Cleaning of micronized dust by moistening, b) Preheating: The cleaned wooden panel is preheated by means of the heating group (B2). subjected to heating to create the optimum surface for hot melt adhesive reaction. bringing it to temperature, c) Dynamic Damping Adhesive Application and Foil Feeding: Foil 15 Feeding via foil shaft (D1), shock absorber module (C4) and glue Mechanical adjustment of tension and thickness deviations in the foil with roller brake (D8) by damping and homogenizing the glue via the nozzle jaw module (C1). the release of the film, d) Synchronous Transmission and Gradual Vacuuming: Foil panel, silicone substrate printing into the vacuum area in such a way that there will be no gap between the roller (D13) transmission; with vacuum adjustment trapezoidal group (E7) according to panel width. by means of a vacuum motor (E5) in a confined closed vacuum area Applying the foil to the grooves and joints, 25 e) Thermal Shock and Cooling (Fixation): Laminated material emerging from the vacuum zone The panel is subjected to cold air flow through the air conditioning hood assembly (E9). by holding it to prevent the foil from stretching back and the glue from hardening acceleration, 30 12 f) Surface Protection: Protective tape module (F) on laminated panel surface The process is completed by applying a protective film. In an alternative configuration of the invention; laminated material is placed at the outlet of the vacuum field (E). 5 in the deep joints and recesses of the PVC foil on the wooden panel a standalone cooling station or for the purpose of instantly fixing its form Integrated air conditioning hood unit (E9) is included. This alternative In the process, the hot and shaped foil emerging from the vacuum zone is cooled. conditioned air is applied from the station or air conditioning hood unit (E9). It is subjected to thermal shock by a cold air stream. Thus, the reaction time of the glue is 10 By shortening the foil, ossification is accelerated due to internal stresses within the foil. The resulting tendency to stretch back (memory effect) is completely suppressed and deepened. The adhesion quality on the profile surfaces is made permanent. 20 30

Claims

13 REQUESTS 1. Wooden panels used in the manufacture of furniture, doors, and wooden structural elements. or hot glue (PUR) PVC and similar thermoplastic foils to door surfaces enabling lamination on a continuous line via hotmelt, at least one 5 coarse brush module (A1), at least one wet brush module (A2), at least one preheating module group (B), at least one movable nozzle jaw group (C), at least one shaft and glue roller module (D), at least one vacuum group (E) and at least one protective tape It is a PVC foil lamination machine containing module (F); its feature is: • The nozzle in question houses the jaw module (C1); cleaning, 10 sensitive machine parameters in repair or maintenance situations The machine moves on linear slides without breaking down. a movable table that can be pulled axially outwards from its body module ( ), • The momentary tension created when unrolling the foil causes a pull of 15 flexible damping in its structure to compensate for force and thickness deviations mechanically absorbs the glue at the nozzle outlet with its elements a shock absorber module (C4) that prevents their accumulation, • Precise rotational resistance during the transfer of hot melt adhesive to the foil surface. 20 by controlling it in this way, it stabilizes the glue film thickness at the micron level. a glue roller brake (D8) and silicone controlled by means of this brake a structured glue roller (D9), • By contacting the bottom surface of the panels that are transmitted continuously along the line. Preventing axial displacement by eliminating gaps between panels Eliminates air leaks and momentary pressure drops in the vacuum area. 25 It has an asymmetric grooved surface structure and a single motor-gearbox group. a silicon substrate pressure roller (D13) driven synchronously via It includes.

2. A PVC foil lamination machine conforming to Claim 1; its feature is that it can laminate wood to a thickness of 30°. The coarse brush in question is used to remove static dust from the panel surface. 14 A coarse brush air comb module (A1.5) is located within module (A1) It includes.

3. A PVC foil lamination machine conforming to Claim 1; its feature is wood. By transferring thermal energy homogeneously to the panel surface, the hot glue cools down instantly. 5 a heater located within the preheating group (B) in question to prevent group (B2) and a heating adjustment plate (B4) that directs the rays emanating from this group It includes.

4. A PVC foil lamination machine conforming to Claim 1; its feature is foil 10 Shaft and glue designed to control oscillations depending on line speed when unwinding from the roll. a shaft brake assembly (D2) and foil located within the roller module (D) A movable adjustment roller (D6) directs the glue to the application area. It includes.

5. A PVC foil lamination machine conforming to Claim 1; its specifications include: Within the vacuum group (E), vacuum according to wood panels of different widths. a vacuum adjustment trapezoidal group (E7) that seals the channel and This includes an integrated vacuum internal seal assembly (E12).

6. A PVC foil lamination machine conforming to Claim 1; its feature is vacuum lamination. by subjecting the foil on the laminated panels coming out of the region to thermal shock To prevent it from stretching back, an air conditioning hood assembly (E9) is an alternative. It is the structure that incorporates it within itself.

7. On the PVC foil lamination machine in any of items 1 to 6. wood panels covered with PVC and similar thermoplastic foils continuously It is a lamination method performed on an inline; its characteristic feature is the following process, in sequence: It includes the following steps: • a) Remove coarse particles from the surface of the wood panel to be processed using a coarse brush 30 Sweeping through module (A1) and blowing through air comb module (A1.5), then moistened in the wet brush module (A2) the micronized powders cleaning, • b) Heaters (B2) in the preheating group (B) of the cleaned panels bringing it to the reaction temperature by means of • c) Opening the foil during shaft brake assembly (D2) control, instantaneous 5 on the foil Shock absorption modulus (C4) and glue of tension and wall thickness deviations homogeneous glue by mechanical damping with roller brake (D8). the release of the film, • d) Asymmetric grooved silicone bottom printing roller (D13) of the foil panel transmitted into a vacuum area in such a way that there is no gap between them and the vacuum 10 Adjustable trapezoidal group (E7) and vacuum motor (E5) in width-limited area by pulling the foil into the panel recesses, • e) Protective tape module (F) applied to the laminated panel surface The process is completed by applying a protective film. 20 30

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