Building Panel Bevel Forming With Indentation and Local Heating
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Solution Overview
Problem
The manufacturing of bevels on building panels, such as Luxury Vinyl Tiles (LVT) and Stone Plastic Composite (SPC) panels, is inefficient due to the hardness of their cores, requiring high temperatures, high pressures, and thick material layers, leading to costly and material-consuming processes.
Innovation Solution
A method involving creating an indentation in the edge of the panel, heating the area, and applying pressure to form a bevel, which can be V-shaped, U-shaped, or arc-shaped, extending between 0.2 mm and 1 mm perpendicular to the surface, and can be curved with a radius of 1 mm to 10 mm, depending on the panel thickness and mechanical locking device dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high temperatures, high pressures, and thick material layers are used to form bevels on hard core panels, then the bevel shape can be achieved, but the manufacturing process becomes inefficient and material-consuming
Solution Approach 1:
The patent applies preliminary action by creating an indentation in the panel surface before forming the bevel. This pre-prepared cavity allows the bevel-forming process to proceed more easily, reducing the need for excessive heat, pressure, and material thickness. The indentation is formed in advance to guide material flow and achieve the desired bevel shape with less intensive processing conditions.
Solution Approach 2:
The patent employs parameter changes by modifying the physical state of the panel material through controlled heating during the bevel-forming process. By adjusting temperature parameters locally at the bevel formation zone, the material becomes more pliable, enabling bevel creation with reduced pressure and material thickness requirements, thus improving manufacturing efficiency while maintaining bevel quality.
2Manufacturing precision
If high temperatures, high pressures, and thick material layers are used to form bevels on hard core panels, then the bevel shape can be achieved, but the manufacturing cost increases
Solution Approach 1:
The patent applies preliminary action by creating an indentation in the panel surface before forming the bevel. This pre-prepared cavity allows the bevel-forming process to proceed more easily, reducing the need for excessive heat, pressure, and material thickness. The indentation is formed in advance to guide material flow and achieve the desired bevel shape with less intensive processing conditions.
Solution Approach 2:
The patent employs parameter changes by modifying the physical state of the panel material through controlled heating during the bevel-forming process. By adjusting temperature parameters locally at the bevel formation zone, the material becomes more pliable, enabling bevel creation with reduced pressure and material thickness requirements, thus improving manufacturing efficiency while maintaining bevel quality.
3Manufacturing precision
If thick layers of material are used to form bevels on hard core panels, then the bevel shape can be achieved, but material consumption increases
Solution Approach 1:
The patent applies preliminary action by creating an indentation in the panel surface before forming the bevel. This pre-prepared cavity allows the bevel-forming process to proceed more easily, reducing the need for excessive heat, pressure, and material thickness. The indentation is formed in advance to guide material flow and achieve the desired bevel shape with less intensive processing conditions.
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 allows for the efficient formation of bevels on previously difficult-to-shape panels, reducing material consumption and processing costs by using temporary indentations that are removed during final shaping, enabling a broader range of materials to be used and improving aesthetic appearance.
Implementation Method 1
heating at least an area between the indentation and the surface of the building panel in which the bevel is to be formed
Implementation Method 2
applying pressure to the surface for forming a bevel of the building panel
Data Source
AI summary
A method to manufacture a bevel at least partly along at least one edge of a building panel, such as a floor panel or wall panel, where the building panel includes a polymer-based material. The method includes creating an indentation in an edge portion of the at least one edge of the building panel, where the indentation is located at a distance from a surface of the building panel, in a direction substantially perpendicular to the surface of the building panel. The method further including heating at least an area between the indentation and the surface of the building panel in which the bevel is to be formed and applying pressure to the surface for forming a bevel of the building panel.