Methods for affixing overlay sheets to concrete form

Abstract

A resin impregnated overlay sheet is laid atop a wood veneer to create a concrete form. At a pre-press station, pressure is applied to a veneer assembly having an overlay sheet laid atop it. Thereafter, the pressed overlaid assembly is transferred for final hot pressing. The pre-pressing of the overlay sheet onto the wood veneer ensures the static adherence of the overlay sheet to the veneer prior to final hot pressing.

1 . A method of manufacturing a form, the method comprising the steps of:
 (a) constructing an assembly comprising a plurality of wood veneers;   (b) cutting the assembly;   (c) cleaning a face of the assembly;   (d) applying an overlay sheet onto the assembly face to create an overlaid assembly; and   (e) applying pressure to the overlaid assembly for a pre-determined period using a non-heated pre-press.   
     
     
         2 . A method as defined in  claim 1 , wherein the form is a concrete form. 
     
     
         3 . A method as defined in  claim 1 , wherein the pressure applied to the unit in step (e) is approximately 155 psi of pressure applied for a period of 4.5-5 minutes. 
     
     
         4 . A method as defined in clam  1 , further comprising the step of transporting the overlaid assembly to a hot press wherein heat is applied for final bonding of the form. 
     
     
         5 . A method as defined in  claim 1 , wherein the overlay sheet is resin impregnated, step (e) further comprising the step of causing the assembly and overlay sheet to stick together in response to the applied pressure. 
     
     
         6 . A method as defined in  claim 1 , wherein the application of the overlay sheet in step (d) is accomplished by a human operator, the overlay sheet being applied without interrupting movement of the assembly line. 
     
     
         7 . A method as defined in  claim 1 , wherein step (d) is performed at a side shift location. 
     
     
         8 . A method as defined in  claim 1 , wherein the overlay sheet is a resin impregnated cellulose-fiber sheet. 
     
     
         9 . A method of manufacturing a form, the method comprising the steps of:
 (a) applying an overlay sheet to an assembly face to create an overlaid assembly;   (b) applying pressure to the overlaid assembly using a non-heated pre-press; and   (c) transporting the overlaid assembly to a separate press for final pressing, thereby creating the form.   
     
     
         10 . A method as defined in  claim 9 , wherein the pressure applied in step (b) is approximately 155 psi of pressure applied for a period of 4.5-5 minutes. 
     
     
         11 . A method as defined in  claim 9 , wherein heat is involved in the final pressing of step (c). 
     
     
         12 . A method as defined in  claim 9 , wherein step (a) is performed at a side shift location. 
     
     
         13 . A method as defined in  claim 12 , wherein step (a) is further performed by a human operator. 
     
     
         14 . A method as defined in  claim 9 , wherein the overlay sheet is a resin impregnated cellulose-fiber sheet.