Floor Panel Edge Machining Layout for Tighter Locking Tolerances
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Solution Overview
Problem
Existing mechanical locking systems for floor panels face challenges in achieving precise production tolerances, particularly with horizontal locking surfaces, due to uncontrolled horizontal turning during machining, which affects the fit and durability of the locking system.
Innovation Solution
A tool configuration where tools forming horizontal locking surfaces are combined on the same side of a column, with preprocessing steps to alter the properties of the wear-resistant surface layer, and the use of COMBI tools or scraping tools to minimize horizontal turning and extend tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate tool configurations are used to form horizontal locking surfaces, then tool life is extended, but production tolerances deteriorate due to uncontrolled horizontal turning during machining
Solution Approach 1:
The patent combines multiple tool configurations into a single integrated tool configuration that forms both the first and second locking surfaces simultaneously. This merging eliminates the horizontal turning that occurs when using separate tool configurations, thereby improving production tolerances while managing tool life through the unified design.
Solution Approach 2:
The patent positions the tool configuration to work from a vertical dimension rather than horizontally across separate stations. By forming both locking surfaces from the same vertical position, the system eliminates horizontal displacement and turning, achieving tighter tolerances without sacrificing tool life.
2Duration of action of moving object
If preprocessing steps are applied to alter surface layer properties, then tool life is extended, but production time increases
Solution Approach 1:
The patent applies preprocessing steps to alter the properties of the wear-resistant surface layer before the main machining operation. This preliminary action prepares the material to be more resistant to tool wear, extending tool life while the integrated tool configuration ensures the additional time does not significantly impact overall production time.
3Manufacturing precision
If tools are positioned on opposite sides of a column, then machining coverage is improved, but horizontal turning increases affecting locking surface accuracy
Solution Approach 1:
The patent merges the functionality of opposite-side tool configurations into a single tool configuration positioned on one side of the column. This unified approach eliminates the horizontal turning between separate tool positions while maintaining comprehensive machining coverage through the integrated design.
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3b
AI summary
The present invention relates to a tool configuration 68, 68' incorporating a preprocessing step 67, 67' and a method incorporating the tool configuration with its preprocessing step, producing an improved locking system of a floor panel 1, 1'. With the special tool configuration, and the preprocessing step changing the properties of the surface layer, certain surfaces are profiled of the joint edge of the floor panel, resulting in decreased tolerances. The present invention relates further to an equipment having an upper belt or chain guided in a horizontal direction, by an upper guiding device, and configured to press the floor panel vertically towards the lower chain, decreasing the tolerances of the produced floor panel as well.