Laminate Board Impressed Regions for Bevel Matching
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Solution Overview
Problem
The existing manufacturing process for laminate panels often results in mismatched bevels during the dissection of boards, leading to unsuitable panels and potential damage to the decorative layers, especially when systematic or occasional errors occur during the dissection process.
Innovation Solution
A method involving a board with impressed regions of defined width, extending over its surface, which allows for dissection with a manufacturing tolerance that compensates for errors, eliminating the need for separate milling of bevels by enhancing mechanical stability and ensuring consistent panel edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the board is dissected along predefined lines to produce panels, then the panels can be manufactured efficiently, but deviations from the ideal dissecting plane cause mismatched bevels and damage to decorative layers
Solution Approach 1:
The press plate impresses bevels and locking profile shapes into the board material before dissection occurs. This preliminary formation of geometric features ensures that even when dissection deviates from the ideal plane, the bevels remain matched because they were pre-formed with tolerance compensation built into their geometry
Solution Approach 2:
The invention changes the geometric parameters of the bevels by impressing them at different depths or angles in different regions of the board. The press plate creates variable bevel geometries that compensate for expected dissection deviations, allowing the bevels to match correctly even when the cut plane shifts
2Manufacturing precision
If milling is used to create locking profiles and bevels after dissection, then precise locking mechanisms can be achieved, but the process becomes time-consuming and material-intensive
Solution Approach 1:
The press plate performs the function of milling locking profiles and bevels during the pressing stage itself, before dissection. The impression means on the press plate directly form the locking profile geometry and bevel shapes in the board material, eliminating the need for subsequent milling operations
Solution Approach 2:
The invention merges multiple manufacturing operations into a single pressing step. The press plate simultaneously performs pressing, bevel formation, and locking profile creation in one operation, combining functions that would traditionally require separate milling steps
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 approach ensures that panels produced, even with errors during dissection, have matching edges and maintain the integrity of the decorative layers, preventing mismatch and damage, thus producing optically perfect flooring with enhanced mechanical stability.
Implementation Method 1
it is desirable to use the press plate to press the bevels into the laminate board so that the bevels do not have to be milled away later in the manufacturing process
Data Source
AI summary
Disclosed is a method for producing panels from a board which includes dissecting the board along predefined lines. The board includes a core material board and is laminated with a laminate material layer. The board is dissected along an impressed region running linear over the complete surface of the laminate material layer. Also disclosed are a press plate, a method for the production of a board having an impressed region, and a board for producing the panels.