Method for forming a panel

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Solution Overview

Problem

Conventional furniture assembly methods often result in exposed locking system components, such as grooves, which can be aesthetically undesirable and may lead to precision issues during the assembly process.

Innovation Solution

A method for producing panels with a mechanical locking system where the edges are covered with a material like laminate or veneer strips in a continuous production line, using a series of edge machines to form precise edge grooves and tongues that cooperate for locking, ensuring the covering material is accurately positioned relative to the edges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a mechanical locking system is used to assemble panels, then the panels can be locked together securely, but the locking components (grooves, tongues) become exposed and aesthetically undesirable

Engineering Contradiction:

Improvelocking securityVSAvoidaesthetic appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The locking system components (edge grooves and tongues) are extracted from the visible surface by being formed within the panel edges themselves, while covering material is applied over these areas to hide them from view, thus removing the aesthetic defect while preserving the locking function

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The locking components are nested within the panel structure, with edge grooves formed along panel edges and tongues inserted into these grooves, all covered by surface material, creating a nested configuration where the functional elements are contained within the aesthetic surface

Inventive Principle:

Principle #7Nested doll (Nesting)

2Shape

If covering material is applied to panel edges after the locking system is formed, then aesthetics are improved, but the positioning precision of the covering material relative to the locking components deteriorates

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidpositioning precision

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The edge grooves are formed in advance during panel production, and the covering material is applied in the same production line with the positioning reference established by the pre-formed grooves, ensuring precise alignment before final assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The processes of forming the locking system and applying the covering material are merged into a single continuous production line operation, eliminating separate positioning steps and ensuring consistent alignment between the covering material and locking components

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If the covering material is attached before forming the edge groove, then the production process is simplified, but cracks arise at the edge groove

Engineering Contradiction:

Improveproduction process simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The edge groove is formed in advance before the covering material is applied, ensuring the panel structure is prepared to receive the covering material without causing cracks or structural damage during the attachment process

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If multiple separate processes are used for edge preparation and covering material attachment, then each process can be optimized independently, but the overall productivity decreases

Engineering Contradiction:

Improveprocess optimizationVSAvoidoverall production efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Multiple processes (edge groove formation, covering material attachment, and panel assembly preparation) are merged into a single continuous production line, eliminating transfer times and setup changes between separate processes, thereby increasing overall productivity while maintaining precision through integrated positioning systems

Inventive Principle:

Principle #5Merging (Combining)

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 allows for improved precision in locking panel edges while covering the locking system components, enhancing the aesthetic appeal and assembly accuracy of furniture products.

Implementation Method 1

displacing the panel in a feeding direction by a conveyor through a first edge machine

Methodology Applied

Scientific EffectMechanical conveyance:

Implementation Method 2

attaching, by a second tool of the first edge machine, a covering material, such as a laminate strip, a thermoplastic strip or a veneer strip, on the first edge

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS10830266B2Method for forming a panel

Publication Date: 2020.11.10 VÄLINGE INNOVATION AB

AI summary

A method for forming a panel for an assembled product including, such as a furniture product, wherein the method includes: displacing the first panel in a feeding direction by a conveyor through a first edge machine, working, by a first tool of the first edge machine, on a first edge of the first panel to obtain a decided location of the first edge, attaching, by a second tool of the first edge machine, a covering material, such as a laminate strip, a thermoplastic strip or a veneer strip, on the first edge, and forming a first edge groove, by a third tool of the first edge machine, along the first edge and on a first main surface of the first panel, wherein the first edge groove is configured to be a part of a locking device.