Heated double diaphragm tool for decorative laminate application
First Claim
1. A panel laminator comprising:
- a first frame defining an outer boundary, the first frame operable to support a panel to be laminated;
a first flexible diaphragm supported by the first frame to cover the outer boundary;
a second frame sized and shaped to conform to the first frame along the outer boundary;
a second flexible diaphragm supported by the second frame to match the outer boundary;
a first heating blanket attached to the first frame distal from the first flexible diaphragm to create an isolated heated environment between the first heating blanket and the first flexible diaphragm, and enclosed by the first frame wherein the first flexible diaphragm and the first heating blanket are separated by a plurality of support bars spanning between first and second lateral portions of the first frame;
a second heating blanket attached to the second frame distal from the second flexible diaphragm to create an isolated heated environment between the second heating blanket and the second flexible diaphragm, and enclosed by the second frame;
a permeable layer positioned between the first flexible diaphragm and the second flexible diaphragm; and
a vacuum port operable to connect a vacuum source to the permeable layer between the first flexible diaphragm and the second flexible diaphragm.
1 Assignment
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Accused Products
Abstract
A panel laminator includes a first frame defining an outer boundary, the first frame operable to support a panel to be laminated and a first flexible diaphragm supported by the first frame to cover the outer boundary. The laminator includes a second frame sized and shaped to conform to the first frame along the outer boundary and a second flexible diaphragm supported by the second frame to match the outer boundary. The laminator includes a passage fluidly connected to the space between the first and second flexible diaphragms, with the passage configured to be coupled to a vacuum system in order to remove air from the space between the first and second flexible diaphragms during a lamination process. The first frame and the second frame are configured to rotate as a unit between a first, generally horizontal, orientation and a second, generally vertical, orientation.
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Citations
20 Claims
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1. A panel laminator comprising:
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a first frame defining an outer boundary, the first frame operable to support a panel to be laminated; a first flexible diaphragm supported by the first frame to cover the outer boundary; a second frame sized and shaped to conform to the first frame along the outer boundary; a second flexible diaphragm supported by the second frame to match the outer boundary; a first heating blanket attached to the first frame distal from the first flexible diaphragm to create an isolated heated environment between the first heating blanket and the first flexible diaphragm, and enclosed by the first frame wherein the first flexible diaphragm and the first heating blanket are separated by a plurality of support bars spanning between first and second lateral portions of the first frame; a second heating blanket attached to the second frame distal from the second flexible diaphragm to create an isolated heated environment between the second heating blanket and the second flexible diaphragm, and enclosed by the second frame; a permeable layer positioned between the first flexible diaphragm and the second flexible diaphragm; and a vacuum port operable to connect a vacuum source to the permeable layer between the first flexible diaphragm and the second flexible diaphragm. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An apparatus for laminating a panel, the apparatus comprising:
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a first flexible diaphragm; a first frame bound to the first flexible diaphragm; a second flexible diaphragm; a second frame bound to the second flexible diaphragm, the second frame configured to be coupled to the first frame so that the first flexible diaphragm is proximate the second flexible diaphragm, thereby creating a space between the first flexible diaphragm and the second flexible diaphragm; a passage fluidly connected to the space between the first flexible diaphragm and the second flexible diaphragm, the passage configured to be coupled to a vacuum system in order to remove air from the space between the first flexible diaphragm and the second flexible diaphragm during a lamination process; and a diaphragm support configured to (a) provide support for the first flexible diaphragm against gravity prior to activation of the vacuum system and (b) be spaced from the first flexible diaphragm after activation of the vacuum system and during the lamination process, wherein the diaphragm support includes a plurality of support bars spanning between first and second lateral portions of the first frame and wherein at least one of the support bars has a three-dimensional shape configured to correspond to a non-planar shape of a panel to be received in a space between the first flexible diaphragm and the second flexible diaphragm; wherein the first frame and the second frame are configured to rotate as a unit between a first, generally horizontal, orientation and a second, generally vertical, orientation. - View Dependent Claims (11, 12, 13)
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14. A method of laminating a panel, the method comprising:
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providing a panel and a laminate to be applied to the panel; providing a first flexible diaphragm bound to a first frame and a second flexible diaphragm bound to a second frame; securing the first frame to the second frame so that the panel and the laminate to be applied to the panel are enclosed within a space between the first flexible diaphragm and the second flexible diaphragm; evacuating air from the space between the first flexible diaphragm and the second flexible diaphragm; and heating an ambient environment around the first flexible diaphragm and the second flexible diaphragm, the panel, and the laminate by activating a first heating blanket attached to the first frame distal from the first flexible diaphragm and a second heating blanket attached to the second frame distal from the second flexible diaphragm, wherein the first flexible diaphragm and the first heating blanket are separated by a plurality of support bars spanning between first and second lateral portions of the first frame. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification