Varying Cross-Section Bevelled Panel Edge for Natural Appearance and Sealing
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Solution Overview
Problem
Existing panel designs fail to convincingly imitate natural panels, particularly in terms of edge structure and appearance, and often suffer from leakage issues due to inconsistent edge alignment.
Innovation Solution
A panel design featuring a non-planar, irregularly varying lowered edge structure along the panel's edge, which includes a constant extreme edge for sealing and can be coated separately, combined with a milling process using tools that move in multiple directions to create the desired shape, enhancing the natural appearance and preventing water leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flat lowered part is provided at the edge of the panel, then the manufacturing process is simple, but the natural appearance of the panel is poor
Solution Approach 1:
The patent applies local quality by providing a lowered part at the edge of the panel with a specific cross-sectional shape that varies along the edge length. The lowered part has a first cross-sectional shape at a first location and a second cross-sectional shape at a second location, creating localized structural variations that simulate natural wood edges while maintaining manufacturing feasibility through controlled geometric complexity.
2Reliability
If the cross-section of the lowered part is constant along the edge, then the manufacturing process is simple, but the sealing between adjacent panels is insufficient
Solution Approach 1:
The patent applies parameter changes by varying the cross-sectional dimensions of the lowered part along the edge length. Specifically, the width of the lowered part changes from a first width at the first location to a second width at the second location, creating a gradient structure that improves sealing performance while remaining manufacturable through controlled parameter variation rather than complex geometric forms.
3Shape
If the extreme edge of the panel is positioned at varying locations along the edge, then the natural appearance is improved, but water leakage occurs between adjacent panels
Solution Approach 1:
The patent applies segmentation by dividing the edge structure into distinct functional zones: a lowered part with varying cross-section for aesthetic purposes and a separate extreme edge at a constant position for sealing functionality. This segmentation allows each zone to optimize its specific function without compromising the other, preventing water leakage while maintaining natural appearance.
4Shape
If the lowered part is coated separately, then the aesthetic appeal is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by providing the lowered part structure before applying the coating. The varying cross-sectional lowered part is formed on the panel edge, and only after this structural preparation is the coating applied to the lowered part. This sequence allows the coating process to be optimized for the specific geometry of the lowered part, enhancing aesthetic appeal while maintaining manufacturing efficiency through structured process planning.
Data Source
AI summary
The invention provides a panel (1) for use in an assembly of panels (1) attached to each other to form a covering. The panel (1) comprises an upper surface (2) and a lower surface (3) each extending within a different main plain, and at least an edge (4) between these surfaces comprising coupling means (5, 6) to couple the panel (1) to coupling means (5, 6) of another panel (1). The upper surface (2) includes a lowered part (7) at said edge (4) and the cross-section of the lowered part (7), perpendicular to the edge (4) of the panel (1), varies along the edge (4). Such a panel (1) provides a good imitation of a panel made of natural materials. The invention also provides an appropriate method as well as an apparatus to make such a panel (1). The invention provides a panel which presents a very good imitation of a panel made of natural materials.