Formed compact elements
Technical Information Sheet No. 11 / 2012
Contents
1. Material specification
2. Forming process
3. Fabrication
3.1 Machining long edges
3.2 Machining short (curved) edges
3.3 Machining apertures
3.4 Fittings and fixtures
4. Applications
4.1 Interior applications and furniture
4.2 Exterior application
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1. Material specification
The specification for formed compact elements
is similar to HPL Compact laminates,
manufactured in accordance with EN 438.
Their components are of similar material and
they are produced in the same high-pressure
press. They may, in some instances also
contain glue lines or thermoplastic layers
dependant upon the manufacturing process.
Irrespective they all have the following superior
properties.
Self supporting
Highly resistant to water and steam
(standard grades)
Highly impact resistant
Meets stringent hygiene standards
Easily cleaned and low maintenance of
both the face and edge.
Non-toxic
Resistant to organic solvents
Fire resistant
Space saving and easily fixed
Wide design possibilities
Low electrostatic loading of surface
Aesthetically pleasing
fig. 1 high pressure moulding
2.2 Forming of modified compact sheets
with machined groove.
In the area where the flat sheet is to be bent
after manufacture, the laminate thickness is
reduced to not greater than 1mm. By inserting
a removable spacer during pressing and curing
the flat sheet, the laminate being of postforming
grade is then formed using a static forming
machine and rigidly clamped until cool. The
rigidity of the curved element is limited by the
thickness of the laminate on the radius.
Formed Compact elements are self-supporting
with rigid, two dimensional curves and have,
like Compact sheets, a decorative face on one
or both sides.
The surface finish can be smooth, satin or
heavily textured, whilst the edges are nonporous.
With formed Compact elements, new design
features are possible to compliment flat
compact sheet. The formed Compact elements
show significant increase in mechanical
strength that can often be exploited in
construction design.
fig. 2 Bending after manufacture or routered groove.
2. THE FORMING PROCESS
Over recent years different processes have
been developed throughout Europe, some of
them protected by patents either pending or
granted and are as follows.
Production of Formed Compact Elements
using rigid high-pressure moulds.
Melamine treated décor papers and phenolic
treated core papers are assembled in ‘L’ or ‘S’
shaped moulds, of a predetermined size and
curved under heat and high pressure, as a
result they will conform to EN 438.
The manufacturer can cut from these self
supporting, double faced sheets, the profile and
size of elements required. See fig. 1.
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2.3 Bending of modified compact sheets
with routered groove.
The modified compact sheet is manufactured
flat in the normal manner, after which a groove
is routered out, leaving a maximum of 1mm
thickness remaining. The width of the groove is
dependant upon the radius required. After
bending to the required profile on a static
machine the void is filled with a high impact
polyurethane resin. fig. 3.
fig 5. notched bend with spacer
fig. 3 Resin filled internal and external corners.
2.4 Formed elements with Compact core
(notched bend principle)
The compact core sheet is either routered to
form a groove profiled on one side with the
channel completed after bonding the face
laminate or with one core sheet square edged
with the adjacent core sheet edge profiled and
separated by a removable spacer until bonding
of the face laminate is completed. Bending to
the required radius is carried out on a static
postforming machine, using two component
adhesives such as epoxide or acrylic (fig. 4 &
5).
2.4.1 Formed compact elements using
prefabricated core
Sections of compact core can be bonded and
screw fixed together to form ‘L’ shaped
components. 0.8mm pf laminates can then be
bonded to the components and postformed as
normal.
fig. 6 prefabricated core
fig 4. Notched bend with routered groove
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2.5 Production of Compact Elements from
sheets of HPL.
Sheets of HPL up to 1mm in thickness with
décor sheets on one or both sides and phenolic
impregnated core sheets, sanded on both sides
are assembled to provide the desired finished
thickness. These are bonded using reactive
adhesives between male and female moulds in
a hydraulic press. Accuracy must be
maintained in the HPL thickness and the mould
profiles to enable a satisfactory bond to be
made. Radii of approximately 100mm can be
achieved with this method and a constant edge
thickness is maintained.
fig. 10 L, U and S form bends
fig. 8
3. Fabrication
The machining of formed compact elements is
generally as described in the Technical
Information sheet No: 10.
fig. 9
2.6 Production of formed compact elements
form compact sheets produced with
Thermoplastic slip layers. figs 8& 9.
2.7 Examples of formed profiles
Depending on the production method used
single or double sided elements can be
produced with radii from as little as 6mm. The
length of the sheet used or the capacity of the
forming machine limits the length of the formed
element. The various profiles possible depend
mainly on the forming process used. The
purchaser should, therefore, determine from
the supplier any production limitations. The
examples depicted in figs. 10 shows some
possibilities.
The recommendation in respect of machines
and tooling apply to formed elements as well as
flat sheet, however, different techniques are
required when cutting across the profile. Care
should be exercised when handling heavy or
large shaped components in order to prevent
damage.
3.1 Machining long edges
The flat edges parallel to the formed axis can
be sawn or routered as normal.
3.2 Machining short edges
Care must be taken when cutting across the
curved profile of the formed elements to avoid
excessive breakout or chipping of the melamine
surface. Special saws and routers are available
that follow the profile and ensure that the
correct cutting angle relative to the face is
maintained.
Alternatively, temporarily supporting the
element throughout the profile and varying by
hand the feed speed past the saw and
maintaining the correct cutting angle can obtain
chip free cutting. Further finishing of the edges
can be carried out by milling and sanding as
required to improve the appearance.
3.3 Machining apertures
Apertures and cut-outs in formed compact
elements should be made using a router either
fixed or hand. All internal corners should be
finished with a 6mm radius to prevent stress
cracking.
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3.4 Fittings and fixtures
Reference should be made to technical
information sheet No: 10 for all fittings.
4. Applications
The use of formed compact elements is
virtually unlimited for interior use, due to the
material properties and high specification. To
ensure the fullest use is made of these
properties it is advisable to contact the
manufacturer at the design stage; this applies
particularly to applications having high specific
requirements.
4.2 Exterior application
Formed compact elements may be used in
certain exterior applications provided that they
conform to Local Authority Regulations and
other specifications. Recommendations issued
by the manufacturer should be followed.
Application area
Pharmacies
Surgeries
Buses and Coaches
Trains
Hospitals
Public houses
Hotels
Laboratories
Cold stores
Abattoirs
Wet rooms
Toilets
Bathrooms
Schools, Sport and leisure
Underground stations
Applications
Kitchen furniture
Bathroom furniture
Office furniture
Escalator cladding
Appliance covers
Shelving
Skirting
Partitions
Wall cladding
Doors
Cubicles
4.1 Interior application and furniture
The various design possibilities permit new and
appealing uses for furniture and indoor use,
such as desks, dado and handrails as well as
windowsills. The high strength and impact
resistance of formed compact elements permit
their use as load bearing structures, and as self
supporting elements in showers and changing
rooms. They are also used for corners and
vanity units, providing a smooth rounded finish
and eliminating sharp edges.
Within the leisure sector, compact has
successfully been used for seating and locker
systems for many years.
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