SPC Floor Chamfer Formation via Rolling Press Deformation
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Solution Overview
Problem
The existing production processes for SPC floors are complicated and damage the wear-resistant and color film layers when forming chamfers, leading to inconsistent paint colors and potential paint spills on the surface.
Innovation Solution
A rolling press and plate press forming process is used to create a chamfer on the plastic floor edges by deforming the wear-resistant, color film, and SPC core layers, eliminating the need for pre-cutting and simplifying the production process while maintaining the integrity of the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the grooving device cuts through all layers (UV layer, wear-resistant layer, color film layer, and SPC core layer) to form a chamfer, then the size and angle of the chamfer can be adjusted freely, but the wear-resistant layer and color film layer are damaged, requiring additional painting processes that cause color inconsistency and potential paint spills
Solution Approach 1:
The invention extracts the cutting action from the grooving device and relocates it to the edge of the pressing roll. By forming the chamfer during the pressing process rather than through separate cutting operations, the wear-resistant layer and color film layer are preserved without damage, eliminating the need for subsequent painting processes
Solution Approach 2:
The invention merges the chamfer formation process with the pressing process by incorporating a chamfer-forming edge on the pressing roll. This integration allows the chamfer to be created during the normal pressing operation without requiring additional cutting or painting steps, thereby simplifying the production process
2Ease of manufacture
If the grooving device only cuts the UV layer and wear-resistant layer to form a micro chamfer, then the production process is simple, but the chamfer size is limited by the wear-resistant layer thickness and the visual effect is poor
Solution Approach 1:
The invention extracts the chamfer formation function from the grooving device and implements it on the pressing roll edge. This allows the pressing roll to simultaneously perform pressing and chamfer formation, maintaining process simplicity while achieving superior chamfer quality that extends through all layers including the color film layer
Solution Approach 2:
The pressing roll is given multi-functionality by adding a chamfer-forming edge to its structure. This modification enables the pressing roll to perform both its primary pressing function and the additional function of forming high-quality chamfers that penetrate through all layers of the floor covering
3Adaptability or versatility
If multiple separate processes (cutting, chamfering, painting) are used to form and treat the chamfer, then the chamfer can be formed regardless of wear-resistant layer thickness, but the production process becomes complicated and production time increases
Solution Approach 1:
The invention merges multiple separate processes (cutting, chamfering, and painting) into a single integrated pressing operation. The chamfer-forming edge on the pressing roll creates the chamfer during pressing, and the heated surface of the roll simultaneously treats the chamfer, eliminating the need for separate cutting and painting steps
Solution Approach 2:
The invention performs the chamfer formation and treatment in advance during the pressing process itself, before the floor covering undergoes subsequent processing steps. This preliminary action eliminates the need for later cutting and painting operations, thereby improving production efficiency
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 forms a seamless joint seam without damaging the wear-resistant layer, improves the appearance, and reduces production complexity by integrating chamfer formation into the rolling press process, similar to wood flooring.
Implementation Method 1
The pressing roll is pressed on a side of the wear-resistant layer film, and the chamfered edge deforms a corresponding part of the second sheet to form the chamfer on the plastic floor
Data Source
AI summary
At least on or near one of its edges a plastic floor includes a chamfer formed during a rolling press and plate press forming process. During the rolling press and plate press forming process of the plastic floor, a chamfer is formed at the periphery on the front surface of the plastic floor. The wear-resistant layer and color film layer at the chamfer are not damaged. When splicing, the chamfers on the two pieces of plastic floor are connected to each other to form a joint seam, and there is no need to cut chamfers at the edge of the floor before grooving, thereby reducing the production process, and improving the appearance of the joint seam.