Thermoplastic Plate Chamfering via Heat and Pressure Displacement
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Solution Overview
Problem
Conventional methods for manufacturing chamfered edges in panel products, such as those for floors, walls, or ceilings, using mechanical machining tools can be costly and aesthetically suboptimal, especially when the upper layer is thin, as they often extend into the adjoining layer, compromising the appearance and performance.
Innovation Solution
A method involving heating the plate-shaped object near the edge and using pressure means to displace the material downward and sideward, with counter pressure ensuring correct displacement, allowing for a chamfered edge depth exceeding the upper layer thickness without exposing the cheaper adjoining layer, using thermoplastic materials that can be bent and shaped without removing material at the edge location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical machining tools are used to remove material at the chamfered edge location, then the chamfered edge can be formed, but the upper layer becomes thinner and the adjoining layer becomes visible, compromising appearance and requiring additional finishing steps
Solution Approach 1:
The patent replaces mechanical machining tools with a combination of heating and pressure application. The thermoplastic upper layer is heated to become pliable, then pressure means displace the material downward and sideward to form the chamfered edge. This substitution eliminates material removal at the edge location, preventing exposure of the adjoining layer and maintaining a continuous, high-quality appearance without requiring additional finishing steps.
Solution Approach 2:
The patent changes the physical state of the upper layer by heating it to its melting or softening point, transforming it from a rigid state to a pliable state. This parameter change enables the material to be displaced smoothly under pressure without fracturing or exposing underlying layers, thereby maintaining manufacturing precision and aesthetic quality while forming the chamfered edge.
2Quantity of substance
If the upper layer thickness is reduced to降低成本, then material costs decrease, but the chamfered edge formation becomes more difficult without exposing the adjoining layer
Solution Approach 1:
By heating the upper layer to its melting or softening point, the patent changes its physical properties, making even thin layers highly pliable and easy to displace. This parameter change enables chamfered edge formation in layers as thin as 0.2 mm without exposing the adjoining layer, thus reducing material costs while maintaining ease of manufacture.
Solution Approach 2:
The patent replaces mechanical machining with a thermomechanical process combining heating and pressure application. This substitution enables effective chamfered edge formation in very thin upper layers that would be impossible to machine without exposing the underlying structure, thereby allowing cost reduction through thinner material usage.
3Manufacturing precision
If material is displaced downward and sideward to form the chamfered edge, then the upper layer can be shaped without removal, but counter pressure is needed to ensure correct displacement
Solution Approach 1:
The patent employs counter pressure means positioned at strategic locations to counterbalance the forces generated by the pressure means during material displacement. This counter-pressure system ensures accurate and controlled displacement of the thermoplastic material, preventing unwanted deformation and achieving precise chamfered edge geometry, thereby maintaining manufacturing precision despite the added 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 produces a high-quality, aesthetically pleasing chamfered edge with a perfectly shaped continuous contour, reducing material costs by avoiding the need for additional finishing steps and maintaining the upper layer's optical and wear-resistant qualities.
Implementation Method 1
heating the plate shaped object near to said edge
Implementation Method 2
engaging the respective edge of said upper surface with pressure means for forming said chamfered edge by locally displacing material of the upper layer in a downward direction
Data Source
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AI summary
A method is provided for manufacturing a chamfered edge with depth (d) along at least one edge of an upper surface of a plate shaped object, wherein at least an upper layer (1) of said plate shaped object comprises a thermoplastic (or similar) material. The method comprises the steps of heating the plate shaped object near to said edge; engaging the respective edge of said upper surface with pressure means (9) for forming said chamfered edge by locally displacing material of the upper layer in a downward direction while displacing a substantially corresponding amount of material of the object in a substantially sideward direction outward of the original boundaries of the object; and removing the amount of material (10) which has been displaced outward of the original boundaries of the object. Further a plate shaped object with an upper surface provided with a. chamfered edge along at least one of the edges of said upper surface is provided.