Decorative Panel Edge Forming via Machined Reference Datum
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Solution Overview
Problem
Existing methods for manufacturing decorative panels with lowered edge areas face challenges such as inaccurate processing, removal of desired edge dimensions, and deformation issues, particularly when dealing with materials having lowered areas, leading to defects and inefficiencies in achieving the desired design.
Innovation Solution
A method involving a discontinuous pressing operation with a press having a pressing mold and machined reference edges to create consistent and repeatable lowered edge areas, where the substrate is pre-heated and the transparent layer is embossed separately to maintain embossing resolution and minimize springback, allowing for precise control over the formation of lower edge areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If larger slabs, boards or sheets are provided with lowered areas first, then the lowered edge areas can be formed on the material, but further processing becomes troublesome and may lead to removal of the entire lowered area or incorrect dimensions
Solution Approach 1:
The reference edge is machined at a predefined distance from the edge of the slab before the lowered areas are formed. This preliminary reference marking enables precise positioning during subsequent cutting and processing operations, ensuring that the lowered edge areas maintain correct dimensions even after the slab is divided into panels.
Solution Approach 2:
The machined reference edge acts as an intermediary element that mediates between the lowered area formation process and the subsequent panel division process. This reference edge provides a stable, measurable datum that guides accurate cutting and positioning, resolving the conflict between forming lowered areas and maintaining processing ease.
2Shape
If milling profiled edges to the panels is performed, then edge profiling can be achieved, but similar undesired results occur with removal of lowered areas or incorrect dimensions
Solution Approach 1:
The reference edge is established before any edge profiling or panel division occurs. This preliminary reference allows subsequent milling operations to be performed with accurate positioning, ensuring that both the profiled edge shape and the lowered edge area dimensions are achieved correctly without interference between operations.
3Shape
If the forming of lowered areas requires high deformation in the substrate, then the lowered edge areas can be formed, but resulting defects occur
Solution Approach 1:
The method changes the approach by introducing a reference edge at a predefined distance rather than relying on high deformation processes. This parameter change in the manufacturing approach reduces substrate deformation and associated defects while still achieving the required lowered edge area shape.
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
This method ensures accurate and repeatable formation of lower edge areas, reducing defects and deformation, and allows for the creation of decorative panels with precise dimensions and design features, such as wood-like patterns, while maintaining the embossing resolution and minimizing springback.
Implementation Method 1
The forming of said lowered areas may require high deformation in the substrate of the slab, board or sheet
Implementation Method 2
said transparent layer may also be provided with excavations for example for the imitation of wood pores
Data Source
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Figure 6
AI summary
Method for manufacturing a decorative panel, comprising at least: - providing a board material (17) with a substrate (7) and a top layer comprising a printed pattern (8) and a transparent layer (9); - providing one or more lowered areas (6A) in said board material (17); - further processing said board material (17) into one or more of said decorative panels (1), wherein at least a portion of said one or more lowered areas (6A) forms a lower edge area (6) at one or both edges (2-3) of a pair of opposite edges of said decorative panels (1); characterized in that said one or more lowered areas (6A) are provided at least by means of a press (23) having a pressing mold (22), wherein at least one reference edge (19-21) is machined at least to said substrate (7), wherein said reference edge (19-21) is at a predefined distance (D1-D2) from at least one edge of said pair of opposite edges (2-3).