Mineral Decorative Panels With Integrated Edge Profiling
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Solution Overview
Problem
Existing laminate and vinyl-based floating floor panels suffer from moisture sensitivity, noise development due to ticking, and material density issues, while existing manufacturing methods lack efficiency and accuracy in forming edge profiles.
Innovation Solution
A method for manufacturing decorative panels involving a substrate and decorative top layer, where the substrate is mineral or thermoplastic, with edge profiles formed during or prior to dividing operations using cutting or continuous forming processes, allowing precise edge alignment and minimal material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laminate floor panels are manufactured with MDF or HDF substrate, then the panels can be produced with standard materials and processes, but the panels become moisture-sensitive and develop ticking noises during use
Solution Approach 1:
The patent changes the fundamental material parameter of the substrate from organic fiberboards (MDF/HDF) to inorganic mineral-based materials. This parameter change eliminates moisture sensitivity while maintaining manufacturability through established mineral board production processes.
2Manufacturing precision
If the top layer extends over bevelled edge portions formed by removing material, then the decorative surface is exposed, but material is wasted and production efficiency decreases
Solution Approach 1:
The patent applies preliminary action by forming the bevelled edge profile during the main production process before the panel is completed. The mineral-containing material is shaped with the desired edge profile during manufacturing, eliminating the need for subsequent material removal and preventing material waste.
Solution Approach 2:
The patent extracts the unnecessary step of material removal from the production process. By forming the edge profile directly during manufacturing, the patent removes the wasteful post-processing operation entirely from the production sequence.
3Manufacturing precision
If vinyl-based floor panels are provided with bevelled edge portions by machining away material, then the edge profile is created, but production time increases and productivity decreases
Solution Approach 1:
The patent merges the edge profiling operation with the main production process. The bevelled edge profile is formed simultaneously with panel manufacturing through integrated molding or shaping operations, eliminating separate machining steps and increasing productivity.
4Productivity
If the decorative top layer is laminated in a continuous operation with longitudinal edges directed transversely to feeding direction, then lamination efficiency is improved, but edge alignment precision may be compromised
Solution Approach 1:
The patent changes the orientation parameter of the panels during lamination. By directing the longitudinal edges of panels transversely to the feeding direction during continuous lamination, the patent optimizes both lamination efficiency and edge alignment precision through improved material flow and positioning.
Data Source
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AI summary
Method for manufacturing a decorative panel, wherein said panel (1) comprises a substrate (2) and a decorative top layer (3), wherein said substrate is a mineral containing substrate and/or a thermoplastic material containing substrate, wherein said substrate and/or decorative top layer is obtained from a larger material (4) by means of a dividing operation (S1), and wherein said dividing operation is performed to divide the larger material into panels in a direction transversely to the feeding direction of said larger material.