Method for forming surface-engraved panels clad with a sheet of thermodeformable material and apparatus for implementing the method

A method for forming rigid substrate panels clad with a sheet of thermodeformable material, comprising the steps of:

• engraving a surface of said substrate to obtain cavities therein according to a predetermined design,
• spreading a thermosoftenable adhesive over the entire engraved surface, including the cavities, of said substrate and to said sheet,
• applying said sheet of thermodeformable material to the engraved surface of the chipboard substrate,
• heating the assembled panel to partially soften said sheet of thermodeformable material covering said cavities and to soften the adhesive within said cavities, while shielding unengraved portions of said engraved surface from heating, and then
• passing the panel through one or more pairs of rollers formed of elastically yieldable material of which the roller in contact with the engraved surface causes the sheet of thermodeformable material, already softened, to penetrate into said cavities so as to adhere to their surfaces.

An apparatus for forming surface-engraved panels clad with a sheet of thermodeformable material, comprising:

• a frame defining a flowpath for a series of panels, each having one engraved surface having cavities formed therein, and with unengraved portions,
• means for heating the engraved surface of the panel, to cause softening of both a sheet of thermodeformable material previously applied to said panel, and an adhesive within said cavities,
• a plurality of pairs of rollers between which the panel is passed, the roller of each pair in contact with the engraved surface being formed of an elastically yieldable material, and
• a plurality of heater elements for heating the surface of the panels and a surface of the rollers, said elements being interposed between successive rollers, one roller of each pair being mounted on fixed supports attached to said frame, and each roller acting on the engraved surface being mounted on supports which are movable with respect to the corresponding fixed supports,
• means for progressively heating the rollers acting on the engraved surface, so that the roller temperatures increase along said flowpath, and further comprising
• heat shields interposed between the heater elements and the panel to shield the unengraved portions of the panel surface.

An apparatus for forming surface-engraved panels clad with a sheet of thermodeformable material, comprising:

• a frame defining a flowpath for a series of panels, each having one engraved surface having cavities formed therein,
• means for heating the engraved surface of the panel, to cause softening of both a sheet of thermodeformable material previously applied to said panel, and an adhesive within said cavities,
• a plurality of pairs of rollers between which the panel is passed, the roller of each pair in contact with the engraved surface being formed of an elastically yieldable material, and
• a plurality of heater elements for heating the surface of the panels and the surface of the rollers, said elements being interposed between successive rollers, one roller of each pair being mounted on fixed supports attached to said frame, and each roller acting on the engraved surface being mounted on supports which are movable with respect to the corresponding fixed supports,
• means for progressively heating the rollers acting on the engraved surface, so that the roller temperatures increase along said flowpath,
• the rollers acting on the engraved surface of the panels are formed of rubber having a hardness which increases progressively along said flowpath, from about 10.degree. Shore to about 45.degree. Shore.