Floor Panel Edge Machining With Non-Rotating Locking Surface Tools
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mechanical locking systems for floor panels face challenges in achieving precise production tolerances, particularly in horizontal locking, due to uncontrolled horizontal turning and increased side pressures during the manufacturing process, leading to inconsistent locking strengths and material inefficiencies.
Innovation Solution
The use of non-rotating carving or scraping tool configurations, where fixed chip-removing surfaces along the feeding direction form at least part of the locking surfaces, allowing for closer tool placement and eliminating horizontal turning tolerances, and potentially forming both pairs of horizontal surfaces with the same tool configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotating cutting tools are used to form locking surfaces, then material can be removed efficiently, but horizontal turning and side pressures cause inconsistent production tolerances
Solution Approach 1:
Instead of using rotating cutting tools that move horizontally across the panel edge, the patent employs stationary carving tools that remain fixed in position while the panel moves linearly past them. This inversion of the cutting mechanism eliminates horizontal turning and the associated side pressures, thereby achieving consistent production tolerances while maintaining efficient material removal through the linear feeding motion.
2Manufacturing precision
If multiple independent tool configurations are used to form both pairs of horizontal locking surfaces, then precise locking can be achieved, but device complexity and production costs increase
Solution Approach 1:
The patent employs a single stationary carving tool configuration that performs multiple functions: it forms both the first pair of horizontal locking surfaces and the second pair of horizontal locking surfaces on opposite edges of the panel. This multi-functional tool eliminates the need for multiple independent tool configurations, reducing device complexity and production costs while maintaining precise locking through the consistent linear motion of the panel during the carving process.
Data Source
AI summary
A tool configuration 91 for producing an improved locking system of a floor panel 1′ and a method incorporating such tool configuration. The tool configuration 91x, 91y, is a non-rotating tool configuration profiling certain surfaces of the joint edge of the floor panel, resulting in that the tolerances can be kept on a low level.