Continuous Covering Panel Embossing Without Die Changes
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Solution Overview
Problem
The traditional process for manufacturing embossed covering panels requires manual insertion and removal of panels in a hydraulic press, leading to downtime and high costs associated with manufacturing different dies for varying patterns.
Innovation Solution
A continuous process using an embossing apparatus that translates embossing tools in both directions along a perpendicular axis to create embossed lines on a continuously conveyed material sheet, allowing for different patterns without the need for new dies, using a system that includes a sheet material carrier, embossing tools, and a controller to manage conveying speed and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hydraulic press is used to emboss covering panels one at a time, then embossing precision can be maintained, but productivity decreases due to manual insertion and removal causing downtime
Solution Approach 1:
The patent implements continuous embossing by feeding covering panels through an embossing apparatus in a continuous stream, eliminating the stop-start nature of traditional hydraulic pressing. The embossing tools continuously engage with the material as it moves through the apparatus, maintaining productive action without interruption from manual loading/unloading cycles
Solution Approach 2:
The patent replaces the traditional hydraulic press mechanism with a continuous mechanical embossing system where panels are conveyed through the embossing apparatus. This substitution eliminates the need for repeated press engagement and disengagement, allowing continuous processing while maintaining embossing quality through controlled mechanical contact
2Adaptability or versatility
If different dies are manufactured for different embossing patterns, then embossing versatility is achieved, but manufacturing cost and time increase
Solution Approach 1:
The patent employs dynamically adjustable embossing tools that can be reconfigured for different patterns without manufacturing new dies. The embossing tools can be positioned, oriented, and programmed to create various patterns, allowing the same physical tooling to adapt to different production requirements through controlled movement and programming rather than physical remanufacturing
Solution Approach 2:
The patent changes operational parameters (tool position, angle, speed, pressure) to create different embossing patterns rather than manufacturing different physical dies. By varying these parameters, the same embossing apparatus can produce multiple patterns, eliminating the need for costly die manufacturing for each pattern variation
3Manufacturing precision
If covering panels are processed one at a time in a hydraulic press, then embossing quality can be controlled, but loss of time increases due to repeated setup and operation cycles
Solution Approach 1:
The patent eliminates idle time between embossing operations by implementing continuous material flow through the embossing apparatus. The embossing action occurs continuously as panels move through the system, removing the downtime associated with loading, positioning, and resetting that occurs in batch processing of individual panels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous embossing of covering panels in any desired pattern, reducing downtime and costs by eliminating the need for manual panel insertion and die changes, and facilitating efficient production of embossed covering panels.
Implementation Method 1
the embossing apparatus comprises a linear screw actuator for each respective embossing tool, the linear screw actuator adapted to translating the respective embossing tool in the both directions along the translation axis
Implementation Method 2
contacting the at least one embossing tool with a surface of the covering material sheet as the covering material sheet traverses the embossing apparatus with a pressure sufficient to create at least one embossing line
Data Source
AI summary
A covering panel comprising at least one embossed line and a process for manufacturing the same are provided. The process includes unrolling continuously a covering material sheet from a supply roll, continuously conveying the covering material sheet along a conveying line towards an embossing apparatus having at least one embossing tool translatable in both directions along an axis perpendicular to the conveyance direction, translating the at least one embossing tool in the both directions along the axis and substantially parallel to covering material sheet, contacting the at least one embossing tool with a surface of the covering material sheet as the covering material sheet traverses the embossing apparatus with a pressure sufficient to create at least one embossing line on the covering material sheet, and cutting the covering material sheet to obtain a covering panel.