Laminated Module And Method Of Manufacturing The Same
20210316525 · 2021-10-14
Inventors
- Jose Manuel Domingo Millan (Cantoria, ES)
- María Tallada Martínez (Cantoria, ES)
- Francisco José Rueda Belmonte (Cantoria, ES)
Cpc classification
B29C63/0026
PERFORMING OPERATIONS; TRANSPORTING
B32B5/245
PERFORMING OPERATIONS; TRANSPORTING
A47B13/086
HUMAN NECESSITIES
B32B2307/714
PERFORMING OPERATIONS; TRANSPORTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2307/4023
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B32B5/18
PERFORMING OPERATIONS; TRANSPORTING
B32B9/005
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A laminated module envisaged for use thereof as a work and/or decorative surface and to a method of manufacturing the same are described. The module includes a laminated board, a first pair of side battens, and a first pair of front battens, wherein the side battens are attached to one another and to a beveled side edge of the board and the front battens are attached to one another and to a beveled front edge of the board.
Claims
1. A laminated module comprising a laminated board, a first pair of side battens, and a first pair of front battens; wherein the laminated board comprises a covering layer and a supporting layer, wherein the covering layer defines an upper surface and the supporting layer defines a lower surface, and wherein the board comprises a first side edge and a first front edge, both beveled such that the upper surface of the board is larger than the lower surface of the board; wherein the first pair of side battens comprises a first side batten and a second side batten; the first side batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; the second side batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; wherein the first pair of front battens comprises a first front batten and a second front batten; the first front batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; the second front batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; wherein: the second longitudinal edge of the first side batten and the first longitudinal edge of the second side batten are beveled at substantially complementary angles and attached to one another; the first longitudinal edge of the first side batten and the first side edge of the board are beveled at substantially complementary angles and attached to one another; the second longitudinal edge of the second side batten and the first side edge of the board are beveled substantially with the same bevel angle and attached to one another; the second longitudinal edge of the first front batten and the first longitudinal edge of the second front batten are beveled at substantially complementary angles and attached to one another; the first longitudinal edge of the first front batten and the first front edge of the board are beveled at substantially complementary angles and attached to one another; the second longitudinal edge of the second front batten and the first front edge of the board are beveled substantially with the same bevel angle and attached to one another; the first end edge of the first side batten and the first end edge of the first front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the first side batten and of the first front batten are substantially perpendicular and the outer face of the first side batten is substantially perpendicular to the outer face of the first front batten; and the first end edge of the second side batten and the first end edge of the second front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the second side batten and of the second front batten are substantially perpendicular, and the outer face of the second side batten is substantially coplanar with the outer face of the second front batten.
2. The module according to claim 1, wherein the first side edge and/or the first front edge of the board is beveled with a bevel angle of between 40° and 50°.
3. The module according to claim 1, wherein the second longitudinal edge of the first side batten and/or the second longitudinal edge of the first front batten is beveled with a bevel angle of between 40° and 50°.
4. The module according to claim 1, wherein the first end edge of the first side batten and/or the first end edge of the second side batten is beveled with a bevel angle of between 40° and 50°.
5. The module according to claim 1, wherein: the first side batten and the second side batten have a length substantially equal to the width of the board, a width substantially equal to the thickness of the board, and a thickness substantially equal to half the thickness of the board; and/or the first front batten and the second front batten have a length substantially equal to the length of the board, a width substantially equal to the thickness of the board, and a thickness substantially equal to half the thickness of the board.
6. The module according to claim 1, wherein at least one of the first side batten, second side batten, first front batten, and second front batten is a laminated batten comprising a covering layer and a supporting layer.
7. The module according to claim 6, wherein: the thickness of the covering layer of the laminated batten is between 2 and 10 mm; and/or the thickness of the supporting layer of the laminated batten is between and 20 mm.
8. The module according to claim 1, wherein the covering layer has a thickness smaller than the supporting layer.
9. The module according to claim 1, wherein: the thickness of the covering layer of the board is between 2 and 10 mm; and/or the thickness of the supporting layer of the board is between 10 and 40 mm.
10. The module according to claim 1, wherein the board comprises a second beveled side edge and the module comprises a second pair of side battens; wherein the second pair of side battens comprises a third side batten and a fourth side batten; the third side batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; the fourth side batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; wherein: the second longitudinal edge of the third side batten and the first longitudinal edge of the fourth side batten are beveled at substantially complementary angles and attached to one another; the first longitudinal edge of the third side batten and the second side edge of the board are beveled at substantially complementary angles and attached to one another; the second longitudinal edge of the fourth side batten and the second side edge of the board are beveled substantially with the same bevel angle and attached to one another; the first end edge of the third side batten and the second end edge of the first front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the third side batten and of the first front batten are substantially perpendicular and the outer face of the third side batten is substantially perpendicular to the outer face of the first front batten; and the first end edge of the fourth side batten and the second end edge of the second front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the fourth side batten and of the second front batten are substantially perpendicular, and the outer face of the fourth side batten is substantially coplanar with the outer face of the second front batten.
11. The module according to claim 1, wherein the board comprises a second beveled front edge and the module comprises a second pair of front battens; wherein the second pair of front battens comprises a third front batten and a fourth front batten; the third front batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; the fourth front batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; wherein: the second longitudinal edge of the third front batten and the first longitudinal edge of the fourth front batten are beveled at substantially complementary angles and attached to one another; the first longitudinal edge of the third front batten and the second front edge of the board are beveled at substantially complementary angles and attached to one another; the second longitudinal edge of the fourth front batten and the second front edge of the board are beveled substantially with the same bevel angle and attached to one another; the second end edge of the first side batten and the first end edge of the third front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the first side batten and of the third front batten are substantially perpendicular and the outer face of the first side batten is substantially perpendicular to the outer face of the third front batten; and the second end edge of the second side batten and the first end edge of the fourth front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal direction of the second side batten and of the fourth front batten are substantially perpendicular, and the outer face of the second side batten is substantially coplanar with the outer face of the fourth front batten.
12. A method of manufacturing a module according to claim 1 comprising: a) providing a laminated board comprising a covering layer and a supporting layer, wherein the covering layer defines an upper surface and the supporting layer defines a lower surface; and wherein the board comprises a first side edge and a first front edge, both beveled such that the upper surface of the board is larger than the lower surface of the board; b) providing a first side batten and a second side batten; the first side batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; the second side batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; wherein the second longitudinal edge of the first side batten and the first longitudinal edge of the second side batten are beveled at substantially complementary angles; wherein the first longitudinal edge of the first side batten and the first side edge of the board are beveled at substantially complementary angles; and wherein the second longitudinal edge of the second side batten and the first side edge of the board are beveled substantially with the same bevel angle; c) providing a first front batten and a second front batten; the first front batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; the second front batten comprising a first longitudinal edge and a second longitudinal edge, an outer face, and a first end edge and a second end edge; wherein the second longitudinal edge of the first front batten and the first longitudinal edge of the second front batten are beveled at substantially complementary angles; wherein the first longitudinal edge of the first front batten and the first front edge of the board are beveled at substantially complementary angles; and wherein the second longitudinal edge of the second front batten and the first front edge of the board are beveled substantially with the same bevel angle; d) attaching the second longitudinal edge of the first side batten and the first longitudinal edge of the second side batten; e) attaching the first longitudinal edge of the first side batten and the first side edge of the board; f) attaching the second longitudinal edge of the second side batten and the first side edge of the board; g) attaching the second longitudinal edge of the first front batten and the first longitudinal edge of the second front batten; h) attaching the first longitudinal edge of the first front batten and the first front edge of the board; and i) attaching the second longitudinal edge of the second front batten and the first front edge of the board.
13. The method according to claim 12, wherein: the first end edge of the first side batten and the first end edge of the first front batten are beveled at substantially complementary angles; and the first end edge of the second side batten and the first end edge of the second front batten are beveled at substantially complementary angles; wherein the method additionally comprises: j) attaching the first end edge of the first side batten and the first end edge of the first front batten such that the longitudinal directions of the first side batten and of the first front batten are substantially perpendicular and the outer face of the first side batten is substantially perpendicular to the outer face of the first front batten; k) attaching the first end edge of the second side batten and the first end edge of the second front batten such that the longitudinal direction of the second side batten and of the second front batten are substantially perpendicular, and the outer face of the second side batten is substantially coplanar with the outer face of the second front batten.
14. The method according to claim 12, wherein steps a) to c) result from the following earlier steps: providing a laminated panel; and cutting the panel to obtain the board, the first side batten, the second side batten, the first front batten, and the second front batten.
15. The method according to claim 14, wherein the step of providing a laminated panel comprises attaching a supporting layer to a covering layer.
Description
DESCRIPTION OF THE DRAWINGS
[0094] These and other features and advantages of the invention will be more clearly understood based on the following detailed description of a preferred embodiment, given only by way of non-limiting illustrative example in reference to the attached figures. These figures are presented in a schematic manner and without necessarily maintaining the scale ratio.
[0095]
[0096]
[0097]
[0098]
[0099]
[0100]
[0101]
DETAILED DISCLOSURE OF THE INVENTION
Laminated Module
[0102] The invention proposes, in its first aspect, a laminated module envisaged for use thereof as a work surface. The laminated module comprises a laminated board (1), a first pair of side battens (2, 3), and a first pair of front battens (4, 5).
[0103] The laminated board (1) has a planar configuration with four edges, particularly a first side edge (1.1), a first front edge (1.2), a second side edge (1.3), and a second front edge (1.4). The board (1) has a length and a width. In this embodiment, the front edges (1.2, 1.4) are longer than the side edges (1.1, 1.3). The front edges (1.2, 1.4) are opposite one another through the width of the board, and the side edges (1.1, 1.3) are opposite one another through the length of the board.
[0104] The board (1) comprises a covering layer (1.10) and a supporting layer (1.20). The covering layer (1.10) defines an upper surface (A), corresponding to the useful surface of the module in a situation in which the module is used as a horizontal work surface, and the supporting layer (1.20) defines a lower surface (B), corresponding to the non-visible surface during use of the module as a work surface. In the embodiment shown in the figures, the supporting layer comprises a reticular reinforcement mesh made, for example, of glass fiber, on its lower face. The upper surface (A) and the lower surface (B) define the thickness of the board (1).
[0105] The first side edge (1.1) and the first front edge (1.2) are beveled such that the upper surface (A) of the board is larger than the lower surface (B) of the board.
[0106] In the module of this first aspect, the first pair of side battens (2, 3) is attached to the first side edge (1.1) of the board (1) and the first pair of front battens (4, 5) is attached to the first front edge (1.2) of the board (1). Nevertheless,
[0107] The first pair of side battens (2, 3) comprises a first side batten (2) and a second side batten (3). The first side batten (2) comprises a first longitudinal edge (2.1), a second longitudinal edge (2.2), an outer face (2.3), a first end edge (2.4), and a second end edge (2.5). The second side batten (3) comprises a first longitudinal edge (3.1), a second longitudinal edge (3.2), an outer face (3.3), a first end edge (3.4), and a second end edge (3.5). Preferably, the first side batten (2) and the second side batten (3) have a maximum length approximately equal to the width of the board (1), a maximum width approximately equal to the thickness of the board (1), and a maximum thickness approximately equal to half the thickness of the board (1).
[0108] The second longitudinal edge (2.2) of the first side batten (2) and the first longitudinal edge (3.1) of the second side batten (3) are beveled at substantially complementary angles β.sub.2, γ.sub.2). The first longitudinal edge (2.1) of the first side batten (2) and the first side edge (1.1) of the board (1) are beveled at substantially complementary angles (β.sub.1, α). The second longitudinal edge (3.2) of the second side batten (3) and the first side edge (1.1) of the board (1) are beveled substantially with the same bevel angle (γ.sub.3, α).
[0109] Preferably, the first side batten (2) and the second side batten (3) are laminated battens with the same composition of layers as the laminated board, with the exception of the reinforcement mesh of the board (1) which is not present in the battens as they have a smaller thickness. In this embodiment, the covering layer of the side battens (2, 3) has a maximum width corresponding to the thickness of the board, and it is the layer which is exposed at the side edge of the constructed module.
[0110] The second longitudinal edge (2.2) of the first side batten (2) and the first longitudinal edge (3.1) of the second side batten (3) are attached to one another along their length.
[0111] The first longitudinal edge (2.1) of the first side batten (2) and the second longitudinal edge (3.2) of the second side batten (3) are attached to the first side edge (1.1) of the board (1).
[0112] The outer face (2.3) of the first side batten (2) is the widest surface of the first side batten (2) and forms the exposed (or outer) face of the side edge of the module, whereas the outer face (3.3) of the second side batten (3) is the widest surface of the second side batten (3) and forms the exposed lower face in the proximity of the side edge of the module.
[0113] The first pair of front battens (4, 5) comprises a first front batten (4) and a second front batten (5). The first front batten (4) comprises a first longitudinal edge (4.1), a second longitudinal edge (4.2), an outer face (4.3), a first end edge (4.4), and a second end edge (4.5). The second front batten (5) comprises a first longitudinal edge (5.1), a second longitudinal edge (5.2), an outer face (5.3), a first end edge (5.4), and a second end edge (5.5). Preferably, the first front batten (4) and the second front batten (5) have a maximum length approximately equal to the length of the board (1), a maximum width approximately equal to the thickness of the board (1), and a maximum thickness approximately equal to half the thickness of the board (1).
[0114] The second longitudinal edge (4.2) of the first front batten (4) and the first longitudinal edge (5.1) of the second front batten (5) are beveled at substantially complementary angles. The first longitudinal edge (4.1) of the first front batten (4) and the first front edge (1.2) of the board (1) are beveled at substantially complementary angles. The second longitudinal edge (5.2) of the second front batten (5) and the first front edge (1.2) of the board (1) are beveled substantially with the same bevel angle.
[0115] The second longitudinal edge (4.2) of the first front batten (4) and the first longitudinal edge (5.1) of the second front batten (5) are attached to one another along their length.
[0116] The first longitudinal edge (4.1) of the first front batten (4) and the second longitudinal edge (5.2) of the second front batten (5) are attached to the first front edge (1.2) of the board (1).
[0117] The outer face (4.3) of the first front batten (4) is the widest surface of the first front batten (4) and forms the exposed (or outer) face of the front edge of the module, whereas the outer face (5.3) of the second front batten (5) is the widest surface of the second front batten (5) and forms the exposed lower face in the proximity of the front edge of the module.
[0118] In the module, the first end edge (2.4) of the first side batten (2) and the first end edge (4.4) of the first front batten (4) are beveled at substantially complementary angles and attached to one another, with the longitudinal direction of said battens forming an approximate angle of 90°, with the outer face (2.3) of the first side batten (2) being substantially perpendicular to the outer face (4.3) of the first front batten (4).
[0119] The first end edge (3.4) of the second side batten (3) and the first end edge (5.4) of the second front batten (5) are beveled at substantially complementary angles and attached to one another, with the longitudinal directions of said battens forming an approximate angle of 90°, and the outer face (3.3) of the second side batten (3) being substantially coplanar with the outer face (5.3) of the second front batten (5). Furthermore, in the preferred embodiment of the module shown in the figures, the outer face (3.3) of the second side batten (3) and the outer face (5.3) of the second front batten (5), which are substantially coplanar with one another, are also substantially coplanar with the lower surface (B) of the board (1).
[0120] In the embodiment shown in
[0121] The second longitudinal edge of the third side batten (6) and the first longitudinal edge of the fourth side batten (7) are beveled at substantially complementary angles (β.sub.4, γ.sub.4) and attached to one another. The first longitudinal edge of the third side batten (6) and the second side edge (1.3) of the board (1) are beveled at substantially complementary angles (R.sub.3, α.sub.1) and attached to one another. The second longitudinal edge of the fourth side batten (7) and the second side edge (1.3) of the board (1) are beveled substantially with the same bevel angle (γ.sub.5, α.sub.1) and attached to one another.
[0122]
[0123] The first end edge (6.4) of the third side batten (6) and the second end edge (4.5) of the first front batten (4) are beveled at substantially complementary angles and attached to one another, with the longitudinal direction of said battens forming an approximate angle of 90°, and the outer face (6.3) of the third side batten (6) being substantially perpendicular to the outer face (4.3) of the first front batten (4). This arrangement can be observed In
[0124] The first end edge (7.4) of the fourth side batten (7) and the second end edge (5.5) of the second front batten (5) are beveled at substantially complementary angles and attached to one another, with the longitudinal direction of said battens forming an approximate angle of 90°, and the outer face (7.3) of the fourth side batten (7) being substantially coplanar with the outer face (5.3) of the second front batten (5). Furthermore, in the preferred embodiment of the module shown in the figures, the outer face (7.3) of the fourth side batten (7) and the outer face (5.3) of the second front batten (5), which are substantially coplanar with one another, are also substantially coplanar with the lower surface (B) of the board (1). This arrangement is seen in
[0125] In the shown embodiment of the module, the second end edge (2.5) of the first side batten (2), the second end edge (3.5) of the second side batten (3), the second end edge (6.5) of the third side batten (6), and the second end edge (7.5) of the fourth side batten (7) are substantially perpendicular to the longitudinal direction of the corresponding batten and substantially coplanar with the second front edge (1.4) of the board, as seen in
[0126] Although the board comprises two beveled side edges and the module comprises two pairs of side battens attached in said beveled side edges in the embodiment of
[0127] Though not shown in the figures, the module may include a second pair of front battens and a second beveled front edge in the board. In this embodiment, the second pair of front battens comprises a third front batten and a fourth front batten. The third front batten comprises a first longitudinal edge, a second longitudinal edge, an outer face, a first end edge, and a second end edge. The fourth front batten comprises a first longitudinal edge, a second longitudinal edge, an outer face, a first end edge, and a second end edge.
[0128] The second longitudinal edge of the third front batten and the first longitudinal edge of the fourth front batten are beveled at substantially complementary angles and attached to one another. The first longitudinal edge of the third front batten and the second front edge of the board are beveled at substantially complementary angles and attached to one another. The second longitudinal edge of the fourth front batten and the second front edge of the board are beveled substantially with the same bevel angle and attached to one another.
[0129] The second end edge of the first side batten and the first end edge of the third front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the first side batten and of the third front batten are substantially perpendicular and the outer face of the first side batten is substantially perpendicular to the outer face of the third front batten.
[0130] The second end edge of the second side batten and the first end edge of the fourth front batten are beveled at substantially complementary angles and attached to one another such that the longitudinal directions of the second side batten and of the fourth front batten are substantially perpendicular, and the outer face of the second side batten is substantially coplanar with the outer face of the fourth front batten.
[0131] In embodiments including a second pair of side battens and a second pair of front battens, the second end edge of the third side batten and the second end edge of the third front batten are beveled at substantially complementary angles and attached to one another, with the longitudinal directions of said battens forming an approximate angle of 90°, and the outer face of the third side batten being substantially perpendicular to the outer face of the third front batten. Preferably, the second end edge of the third side batten and the second end edge of the third front batten are beveled at about 45° in the plane formed by the longitudinal direction and the direction of the thickness of the corresponding batten. Furthermore, the second end edge of the fourth side batten and the second end edge of the fourth front batten are beveled at substantially complementary angles and attached to one another, with the longitudinal directions of said battens forming an approximate angle of 90°, and the outer face of the fourth side batten being substantially coplanar with the outer face of the fourth front batten. Preferably, the second end edge of the fourth side batten and the second end edge of the fourth front batten are beveled at about 45° in the plane formed by the longitudinal direction and the direction of the width of the corresponding batten.
[0132] Preferably, in this embodiment, the outer faces of the second side batten, the second front batten, the fourth side batten, and the fourth side batten are substantially coplanar, and more preferably also coplanar with the lower surface of the board, such that they form a continuity in the lower surface of the module.
[0133] In preferred embodiments, the side and front battens are laminated battens comprising a covering layer and a supporting layer. The covering layers (3.10, 5.10) and supporting layers (3.20, 5.20) of the second side batten (3) and the second front batten (5) are identified in
[0134] In the board (1), the covering layer (1.10) is preferably thinner than the supporting layer (1.20). Preferably, the thickness of the covering layer (1.10) of the board (1) is comprised between 2 and 10 mm, and more preferably between 3 and 8 mm. Preferably, the thickness of the supporting layer (1.20) of the board (1) is comprised between 10 and 40 mm, and more preferably between 15 and 35 mm. In the case of the battens, preferably, the thickness of the covering layer (3.10, 5.10) is comprised between 2 and 10 mm, and more preferably between 3 and 8 mm, and the thickness of the supporting layer (3.20, 5.20) is comprised between 5 and 20 mm, and more preferably between 7 and 17 mm.
[0135] In one embodiment, the materials of the laminated board and the laminated battens are the same. This allows obtaining the board and the battens by means of cutting one and the same initial laminated panel.
[0136] In one embodiment, the material of the covering layer of the laminated battens is the same material as that of the covering layer of the laminated board. In this embodiment, the material of the supporting layer of the laminated battens may be the same as or different from the material of the supporting layer of the laminated board; in particular, the supporting layer of the laminated battens and the supporting layer of the laminated board may differ in terms of materials in the presence of a reinforcement mesh and/or an embellishing sheet in the supporting layer of the board which is not present in the supporting layer of the laminated battens. If the reinforcement mesh and/or the embellishing sheet are present on the lower face of the supporting layer, it is also possible in this embodiment to obtain the board and the battens by means of cutting one and the same initial laminated panel, providing the battens with a thickness smaller than the thickness of the board, such that the area of the supporting layer containing the reinforcement mesh and/or the embellishing sheet which remains on the board is eliminated from the battens.
[0137] The battens can be attached to the board and to one another by means of any known method. Preferably, the battens are adhered by means of an adhesive, such as an epoxy adhesive or a polyurethane-based adhesive, by means of physical anchoring, or by heat sealing.
[0138] For use thereof as a work surface, such as a (kitchen or bathroom) worktop, counter, top board of furniture, and similar applications, the module preferably has a rectangular shape. Preferably, the length of the module is comprised between 0.5 and 3.5 meters, more preferably between 1.0 and 3.2 meters, and even more preferably between 1.5 and 3.0 meters. Preferably, the width of the module is comprised between 0.4 and 0.7 m, and more preferably between 0.5 and 0.65 m. Preferably, the thickness of the module is comprised between 15 and 45 mm, and more preferably between 20 and 40 mm.
Method of Manufacturing a Module
[0139] In a second inventive aspect, the invention proposes a method of manufacturing a module according to the first inventive aspect. The method comprises the following steps:
[0140] a) providing a laminated board (1) comprising a covering layer (1.10) and a supporting layer (1.20), wherein the covering layer (1.10) defines an upper surface (A) and the supporting layer (1.20) defines a lower surface (B); and wherein the board (1) comprises a first side edge (1.1) and a first front edge (1.2), both beveled such that the upper surface (A) of the board is larger than the lower surface (B) of the board;
[0141] b) providing a first side batten (2) and a second side batten (3); the first side batten (2) comprising a first longitudinal edge (2.1) and a second longitudinal edge (2.2), an outer face (2.3), and a first end edge (2.4) and a second end edge (2.5); the second side batten (3) comprising a first longitudinal edge (3.1) and a second longitudinal edge (3.2), an outer face (3.3), and a first end edge (3.4) and a second end edge (3.5); wherein the second longitudinal edge (2.2) of the first side batten (2) and the first longitudinal edge (3.1) of the second side batten (3) are beveled at substantially complementary angles; wherein the first longitudinal edge (2.1) of the first side batten (2) and the first side edge (1.1) of the board (1) are beveled at substantially complementary angles; and wherein the second longitudinal edge (3.2) of the second side batten (3) and the first side edge (1.1) of the board (1) are beveled substantially with the same bevel angle;
[0142] c) providing a first front batten (4) and a second front batten (5); the first front batten (4) comprising a first longitudinal edge (4.1) and a second longitudinal edge (4.2), an outer face (4.3), and a first end edge (4.4) and a second end edge (4.5); the second front batten (5) comprising a first longitudinal edge (5.1) and a second longitudinal edge (5.2), an outer face (5.3), and a first end edge (5.4) and a second end edge (5.5); wherein the second longitudinal edge (4.2) of the first front batten (4) and the first longitudinal edge (5.1) of the second front batten (5) are beveled at substantially complementary angles; wherein the first longitudinal edge (4.1) of the first front batten (4) and the first front edge (1.2) of the board (1) are beveled at substantially complementary angles; and wherein the second longitudinal edge (5.2) of the second front batten (5) and the first front edge (1.2) of the board (1) are beveled substantially with the same bevel angle;
[0143] d) attaching the second longitudinal edge (2.2) of the first side batten (2) and the first longitudinal edge (3.1) of the second side batten (3);
[0144] e) attaching the first longitudinal edge (2.1) of the first side batten (2) and the first side edge (1.1) of the board (1);
[0145] f) attaching the second longitudinal edge (3.2) of the second side batten (3) and the first side edge (1.1) of the board (1);
[0146] g) attaching the second longitudinal edge (4.2) of the first front batten (4) and the first longitudinal edge (5.1) of the second front batten (5);
[0147] h) attaching the first longitudinal edge (4.1) of the first front batten (4) and the first front edge (1.2) of the board (1);
[0148] i) attaching the second longitudinal edge (5.2) of the second front batten (5) and the first front edge (1.2) of the board (1).
[0149] In one embodiment, the first end edge (2.4) of the first side batten (2) and the first end edge (4.4) of the first front batten (4) are beveled at substantially complementary angles; and the first end edge (3.4) of the second side batten (3) and the first end edge (5.4) of the second front batten (5) are beveled at substantially complementary angles. In this embodiment, the method additionally comprises the following steps:
[0150] j) attaching the first end edge (2.4) of the first side batten (2) and the first end edge (4.4) of the first front batten (4) such that the longitudinal directions of the first side batten (2) and of the first front batten (4) are substantially perpendicular and the outer face (2.3) of the first side batten (2) is substantially perpendicular to the outer face (4.3) of the first front batten (4);
[0151] k) attaching the first end edge (3.4) of the second side batten (3) and the first end edge (5.4) of the second front batten (5) such that the longitudinal directions of the second side batten (3) and of the second front batten (5) are substantially perpendicular, and the outer face (3.3) of the second side batten (3) is substantially coplanar with the outer face (5.3) of the second front batten (5).
[0152] The battens of the pair of side battens can be attached to the board individually, or, alternatively, the first side batten and the second side batten can be attached to one another, and the side batten assembly is then attached to the first side edge of the board. Similarly, the battens of the pair of front battens can be attached to the board individually, or, alternatively, the first front batten and the second front batten can be attached to one another, and the front batten assembly is then attached to the first front edge of the board.
[0153] The attachment steps can be performed by means of using an adhesive or any other attachment system.
[0154] Preferably, both the board (1) and the battens (2, 3, 4, 5) have one and the same configuration of layers, at least in the part closer to the external part of the covering layer. In this case, both the laminated board and the laminated side and front battens can all be obtained from one and the same initial laminated panel. Advantageously, this significantly simplifies module manufacture and considerably reduces waste generation.
[0155] In one embodiment, in an initial step, a supporting layer is attached to a covering layer to produce an initial laminated panel with a desired thickness and with a length and width greater than the length and width of the board. The thickness of the initial laminated panel will be the desired thickness of the laminated board. By means of a cutting tool, both the laminated board with the beveled edges, and the side battens and front battens, are cut out from said initial laminated panel. The cuts can be made at suitable angles to produce the described bevels or the cuts can be made at other angles, for example, at right angles, and beveling is then performed. Once the laminated board and the side and front battens are obtained with the beveled edges, the step of attaching the battens to the board proceeds as described.
[0156] The method may include one or more additional steps for cutting, finishing, and/or working the laminated module to adapt it to its final application. Therefore, the method may include a step of cutting the module to the size required by the application, a step for chamfering the borders of the module, and/or a step for cutting out at least one hole for the insertion of an element such as a sink or a cooking plate. Advantageously, these steps can be performed with conventional cutting tools in woodworking or carpentry.
Example of a Laminated Module According to the Invention and of the Method of Manufacturing the Same
[0157] An example of a laminated module according to the invention and of the method of manufacturing the same are described below. In this example, an initial laminated panel is obtained by means of adhering, with a commercial epoxy resin, a commercial polyisocyanurate (PIR) foam slab having a density of 60 kg/m.sup.3, a length of 3.2 m, and a width of 0.75 m, to the lower (‘non-visible’) face of a commercial Dekton® slab with a thickness of 4 mm and a density of 2500 kg/m.sup.3 previously reinforced with a glass mesh, and with the same length and width as the foam slab. The final thickness of the initial laminated panel is 30 mm. The PIR foam slab will form the supporting layer of the laminate, whereas the reinforced Dekton® slab will form the covering layer of the laminated module.
[0158] Other materials for both the supporting layer and the covering layer are possible, without departing from the inventive concept of the present invention. Therefore, the supporting layer can be made up of polymer materials, thermoplastic materials, or thermosetting materials, that are foamed or not foamed, and reinforced (for example, with fillers and/or fibers) or not reinforced, such as polyurethane, polystyrene (extruded or expanded), polyethylene, polypropylene, PVC, among others. Alternatively, the supporting layer can be made up of wooden materials, such as compacted fiber boards or wood particle boards, such as MDF. Other possible materials for the supporting layer are those based on inorganic materials, such as concrete, cements, geopolymers, gypsums, etc., which are porous or non-porous, and reinforced with fillers and/or fibers or not reinforced. The supporting layer can be formed by a laminate having several sheets of materials with different characteristics. Therefore, for example, the supporting layer can be formed by a laminate with a polymeric foam laminated to a layer of fiber mesh, a metal sheet, or a plastic sheet.
[0159] In terms of the covering layer, any material used today as a work surface, such as worktops, can be used. Preferably, a material providing the required mechanical strength and chemical resistance, and preferably having good esthetic qualities (for example, relative to color patterns, shine, and/or type of surface finishing) is selected for the covering layer for this application. The examples of materials which can be used for the covering layer are ceramic materials obtained from mineral sintering, such as porcelain materials, natural stones (for example, granite or marble), and artificial stones of the composite type, such as quartz or bauxite composites. The use of high-density wood laminates or solid wood boards as the covering layer can also be envisaged.
[0160] According to this example, a rectangular laminated board (1) with a maximum length L=3.0 m and a maximum width w=0.6 m is cut from the initial laminated panel using a precision cutting tool. The cuts for the first side edge (1.1) and the second side edge (1.3) and for the first front edge (1.2) of the laminated board are made at an angle α=45°, generating a larger surface on the upper (or useful) face (A) of the board, defined by the covering layer (1.10), and a smaller surface on the lower face (B) of the board (1), away from the covering layer.
[0161] Four side battens are cut from the same initial laminated panel. The side battens are cut with a length (L.sub.L) approximately equal to the width (w) of the laminated board, that is, 0.6 m, and with a maximum width (w.sub.L) approximately equal to the thickness (t) of the board, that is, w.sub.L=t=30 mm. The side battens are cut such that they are beveled at an approximate angle of 45° along their length to configure the beveled longitudinal edges (2.1, 2.2, 3.1, 3.2, 6.1, 6.2, 7.1, 7.2), such that the widest face of the batten which defines the outer face of the batten is the one corresponding to the covering layer (Dekton® in this example) and the maximum thickness (t.sub.L) of the batten is about half the thickness (t) of the board, that is, 15 mm. The longitudinal cuts are made to form an approximate angle of 45° on each side of the batten, in the plane formed by the width (w.sub.L) and the thickness (t.sub.L) of the side battens. Therefore, the plane containing the outer face and the plane containing the longitudinal edge form an approximate angle of 45° on each side of the batten.
[0162] The four side battens include a first side batten (2), a second side batten (3), a third side batten (6), and a fourth side batten (7).
[0163] A first end of the first side batten (2) and of the third side batten (6) is cut at an approximate angle β=45° in the plane formed by the direction of the length (L.sub.L) of the batten and the thickness (t.sub.L) thereof, as schematically illustrated in
[0164] In
[0165] Moreover, as schematically shown in
[0166] Two front battens (4, 5) are additionally cut from the same initial laminated panel (
[0167] The two front battens are a first front batten (4) and a second front batten (5). The two ends of the first front batten (4) are cut at an approximate angle δ=45° in the plane formed by the direction of the length (L.sub.F) of the batten and the thickness (t.sub.F) thereof, as schematically illustrated in
[0168] Moreover, the two ends of the second front batten (5) are cut at approximate angles θ1=45° in the plane formed by the length (L.sub.F) and the width (w.sub.F) of the batten. The first end edge (5.4) and the second end edge (5.5) of the second front batten (5) are thus formed. The cut is made such that the plane containing the end edge (5.4, 5.5) forms an approximate angle of 90° with the plane containing the outer face (5.3) of the batten, and where the area of the first longitudinal edge (5.1) is larger than the area of the second longitudinal edge (5.2). This is illustrated in
[0169] In this example, the module is formed by the seven mentioned parts, i.e., the laminated board (1), the first side batten (2), the second side batten (3), the third side batten (6), the fourth side batten (7), the first front batten (4), and the second front batten (5). In this example, the second front edge (1.4) of the board, which will form a front edge of the module is cut at 90°, without battens adhered thereto, and with the supporting layer (1.20) exposed. In a situation in which the module is used, this second front edge (1.4) will be concealed facing a wall or a piece of furniture, and, therefore, the reinforcement or a more esthetic finishing thereof is not necessary. In other embodiments, the module may include a different number of pairs of battens, for example a single pair of side battens attached to a side edge of the board and a single pair of front battens attached to a front edge of the board, or two pairs of front battens and two pairs of side battens attached, respectively, to the side and front edges of the board. Furthermore, although the bevel angles are about 45° in this example, other angle values are possible for the different cuts, and the same bevel angle for all the battens is not necessary either.
[0170] For the construction of the module, in this example, the first side batten (2) and the second side batten (3) are attached to one another, the third side batten (6) and the fourth side batten (7) are attached to one another, and the first front batten (4) and the second front batten (5) are attached to one another. In this example, the attachment is carried out with an adhesive. After the formation of the three batten assemblies (two side batten assemblies and one front batten assembly), the batten assemblies are attached with an adhesive to the beveled side and front edges, respectively, of the board.
[0171] Once the laminated board (1) has been attached to the batten assemblies, the covering layer (1.10) of the board (1) forms the upper surface (A) of the module. The covering layers (2.10, 6.10) of the first side batten (2) and the third side batten (6) form the side edges of the module, whereas the covering layer (4.10) of the first front batten (4) forms a front edge of the module. The covering layers (3.10, 7.10, 5.10) of the second side batten (3), the fourth side batten (7), and the second front batten (5) form the lower surface of the module in the proximity of the side edges and the front edge. The rest of the lower surface of the module is formed by the lower surface (B) of the board (1). In the embodiment depicted in the figures, these covering layers (3.10, 7.10, 5.10) of the second and fourth side battens, and the second front batten, are substantially coplanar, and they are also coplanar with the lower surface of the board.
[0172] The invention is not limited to this described way of manufacturing the module, but rather another order of steps, or the performance of two or more steps simultaneously, is possible without departing from the inventive concept. Therefore, for example, it is possible to gradually attach the different battens individually to the board with an adhesive.
[0173] The laminated module that is obtained as described has an improved esthetic aspect, as the edges and the lower part in the proximity of the edges are of the same material as the upper surface or useful surface of the module. Furthermore, the edges are more resistant to peeling, impacts, and mechanical or chemical aggressions than the previously known modules. Additionally, the module having a part of the covering layer (3.10, 5.10, 7.10) on its lower face in the proximity of the edges gives it additional resistance in that area, which is often subjected to mechanical or chemical aggressions as it is exposed in the lower part of a kitchen worktop or the like, and/or as it constitutes the area most affected by the vapors of home appliances (ovens, dishwashers) installed below the worktop.
[0174] The module of the invention is much more lightweight than monolayer stone or ceramic boards of a similar size and may be cut or produced with conventional carpentry tools, where specific marble working tools are not required. Furthermore, since the edges are better protected, it better withstands transport and minor impacts in the area of the edges.
Bending Strength Testing
[0175] By way of experiment, a module was prepared as described in the example. An initial laminated panel having a thickness t=30 mm was prepared with the same composition of layers described above, i.e., with a covering layer formed by a Dekton® sheet having a thickness t.sub.c=4 mm, reinforced with a glass fiber mesh, and a PIR foam supporting layer. One board, two pairs of side battens, and one pair of front battens were cut from that initial panel, and a module according to the invention was manufactured as described. Moreover, by way of comparison, a second board of the same dimensions as the previous board, but with the edges cut at 90° with respect to the plane formed by the length and the width of the board, was cut from the same initial panel. To prepare a comparative module with the second board, reinforced Dekton® strips having a thickness of 4 mm were adhered to each of the four edges of the second board using an adhesive.
[0176] A hole, like those made for inserting a glass ceramic plate in a worktop, is made in the two modules thus constructed. The hole had dimensions of 50×50 cm and was made at a distance of 5 cm from the front edge of each module.
[0177] A bending strength test of the two modules was performed by placing, in both cases, different increasing weights in the area of the module located between the front edge of the module and the hole. In the case of the module according to the invention, the edge and the module were capable of supporting 75 kg before showing small cracks. On the other hand, the comparative module with the edges finished at an angle of 90° with an adhered Dekton® strip showed cracks when kg were applied and broke when a weight of 70 kg was applied. As a result of the experiment, it can be concluded that the modules according to the invention show higher mechanical strength.