Laser-Cut Flooring Blanks With Integrated Profiled Edges
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Solution Overview
Problem
The existing methods for producing floor blanks with profiled edges are labor-intensive and involve separate steps for cutting and creating the profiled contour, leading to material loss and tool wear.
Innovation Solution
A floor blank with a multi-layer structure, featuring a wear layer, decorative layer, and reinforcement layer, where the profiled contour is produced entirely by a laser tool with a cutting nozzle aligned perpendicularly to the surface, merging a chamfer or rounding into a convex contact curve and an inclined rectilinear section, allowing for simultaneous cutting and contouring in a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate cutting and contouring steps are used, then manufacturing precision is improved, but productivity deteriorates and manufacturing effort increases
Solution Approach 1:
The patent combines cutting and contouring operations into a single laser processing step. The laser beam simultaneously performs both functions by adjusting focal position during one continuous operation, eliminating the need for separate machining steps and thereby increasing productivity while maintaining edge profile precision through controlled focal point variation.
Solution Approach 2:
The laser performs preliminary cutting to create the basic edge geometry, then immediately follows with contouring in the same operational sequence. This preliminary action approach allows the process to establish the fundamental shape first, then refine it with the profiled contour in a seamless continuous operation, improving overall manufacturing efficiency.
2Manufacturing precision
If multiple processing steps are used, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The laser processing system merges cutting and contouring into one integrated operation. By controlling the focal point position dynamically during a single pass, the system achieves both precise cutting and accurate profiled contour creation simultaneously, eliminating the time required for separate processing steps while maintaining high manufacturing precision.
Solution Approach 2:
The laser operates continuously throughout the entire edge processing operation without interruption or repositioning between cutting and contouring. This continuous useful action is achieved by varying the focal point position along the cutting path, allowing both operations to occur in an unbroken sequence that minimizes processing time while preserving contour accuracy.
3Ease of manufacture
If conventional cutting tools are used, then ease of manufacture is maintained, but tool wear occurs and material loss increases
Solution Approach 1:
The patent replaces mechanical cutting tools with a laser-based thermal processing system. This substitution eliminates tool wear entirely and reduces material waste through more precise energy-controlled cutting. The laser beam delivers the necessary cutting action through thermal energy rather than mechanical contact, maintaining manufacturing simplicity while significantly reducing substance loss.
Solution Approach 2:
The laser processing system utilizes controllable parameters such as power, focal position, and scanning speed to optimize the cutting and contouring process. By adjusting these parameters, the system achieves clean cuts with minimal material waste and eliminates the need for tool changes or maintenance, thereby improving ease of manufacture while reducing material loss.
4Device complexity
If separate cutting and contouring operations are performed, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The laser processing system is designed with multi-functionality, capable of performing both cutting and contouring operations with a single device configuration. By making the laser system universal, the patent eliminates the need for multiple specialized devices while maintaining operational simplicity. The same laser apparatus executes both functions by varying focal position, thereby increasing productivity without significantly increasing device complexity.
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 reduces manufacturing effort, eliminates tool wear, and achieves cost-effectiveness by integrating cutting and contouring into a single step, resulting in efficient production of floor blanks with reduced waste and improved edge contact for seamless flooring.
Implementation Method 1
the profiled contour is produced entirely by a laser tool
Implementation Method 2
A laser tool is used to cut the flooring membrane into flooring sections
Data Source
AI summary
The invention relates to a method for providing flooring blanks (10a, 10b) from a flooring web, comprising the following steps: cutting the flooring web into a plurality of flooring blanks (10a, 10b), wherein at least one edge (11, 12) is created on each of the flooring blanks (10a, 10b); and producing a profiled contour (20) on the edge (11, 12), wherein the contour (20) has a chamfer or rounding (21) on an upper region of the edge and forms an undercut (26) on a lower region. According to the invention, a laser tool is used for cutting the flooring web (10a, 10b), by means of which the profiled contour (20) is produced in one pass during cutting. The invention further relates to a flooring blank (10a, 10b) having profiled edges (11, 12).