Method of manufacturing a panel, provided with a frame foamed of synthetic material at least at one lateral face thereof, as well as a panel obtained through the method

Claim 1

A method of manufacturing a panel, having a porous particle board core and a frame of foamed synthetic material molded in a cavity formed along at least one side edge of said core, comprising the steps of: (a) providing first and second communicating channels in said core, said first channel having a depth less than the panel thickness and said second channel connecting said first channel with said at least one side edge of said core; (b) coating said second channel with a gas-impermeable material; (c) providing at least one vent in said core, said vent having a depth less than the panel thickness, through which ambient air in said cavity can leave said cavity during molding, migrating first through said porous core itself; (d) placing said particle board core into a mold, said cavity being defined along at least that part of the circumference of said core corresponding to said at least one side edge, for forming said frame; (e) closing and sealing a cover over said cavity, without sealing said first channel and said at least one vent; (f) filling said cavity with a curable bi-component foamable synthetic material through said first and second channels, at low pressure, the formation of bubbles being substantially prevented by said gas impermeable coating, said material foaming through an exothermic reaction, said exothermic reaction sufficiently increasing the pressure and temperature of said foaming material to force said ambient air out of said cavity towards said at least one vent and to force said material to penetrate the interstices of the adjacent sections of said core prior to curing; and, after curing, (g) removing said panel from said mold, said frame material having so penetrated said porous particle board core that said frame is integral therewith and not easily separated therefrom.

Claim 2

A method of manufacturing a panel, having a porous particle board core and a frame of foamed synthetic material molded in a cavity formed along at least one side edge of said core, comprising the steps of: (a) providing first and second communicating channels in said core, said first channel having a depth less than the panel thickness and said second channel connecting said first channel with said at least one side edge of said core; (b) coating said second channel with a gas-impermeable material; (c) providing at least one vent in said core, said vent having a depth less than the panel thickness, through which ambient air in said cavity can leave said cavity during molding, migrating first through said porous core itself; (d) placing said particle board core into a mold, said cavity being defined along at least that part of the circumference of said core corresponding to said at least one side edge, for forming said frame; (e) closing and sealing a cover over said cavity, without sealing said first channel and said at least one vent; (f) filling said cavity with a curable bi-component foamable synthetic material through said first and second channels, at low pressure, the formation of bubbles being substantially prevented by said gas impermeable coating, said material foaming through an exothermic reaction, said exothermic reaction sufficiently increasing the pressure and temperature of said foaming material to force said ambient air out of said cavity towards said at least one vent and to force said material to penetrate the interstices of the adjacent sections of said core prior to curing; and, after curing, (g) removing said panel from said mold, said frame material having so penetrated said porous particle board core that said frame is integral therewith and not easily separated therefrom.