method for producing mechanical locking systems on a floor panel

专利摘要:
METHODS AND PROVISIONS RELATED TO MACHINING EDGE OF PANELS FOR CONSTRUCTION. The present invention relates to a tool configuration (68, 68 ') that incorporates a pre-processing step (67, 67') and a method of incorporating the tool configuration with its pre-processing step, producing a improved locking system of a floor panel (1.1 '). With the special tool configuration, and the pre-processing step changing the properties of the surface layer, certain surfaces are profiled from the pivot edge of the floor panel, resulting in decreased tolerances. The present invention also relates to equipment that has an upper chain or belt guided in a horizontal direction, by an upper guide device, and configured to compress the floor panel vertically in the direction of the lower chain, also decreasing the panel tolerances. of floor produced.
公开号:BR112012001979B1
申请号:R112012001979-1
申请日:2010-07-08
公开日:2020-12-22
发明作者:Darko Pervan；Marcus Bergelin；Christian Boo
申请人:Välinge Innovation AB；
IPC主号:

专利说明:

Technical Field
[001] The present invention generally relates to the mechanical locking of floor panels. Specifically, the present invention relates to a tool configuration for producing improved locking systems for mechanical locking of floor panels comprising means for pre-processing the top surface layer of the floor panel as well as the method using such tool configuration. Additionally, the present invention relates to equipment for producing improved locking systems for mechanical locking of floor panels with the use of a guiding device to guide the belt or upper chain as well as guiding the floor panel between two tool configurations. Order Field
[002] The present invention is suitable, particularly for use on floating floors with a mechanical locking system at the edges, which has a wear resistant top surface layer, for example, laminate floors with a laminate surface layer. high pressure or direct laminate, mineral granulated floor tiles, wood fiber mix and the like. The following description of prior art, problems of known systems as well as objects and characteristics of the invention will then be addressed mainly in this order field and the profile of long edge mechanical locking systems as non-limiting examples. However, it should be emphasized that the invention can be used on any floor panels or wall panels, which have a wear-resistant top surface layer and are intended to be joined by means of a mechanical locking system. A traditional wooden floor or wall panel can, for example, use the invention when it is coated with a wear layer comprising wear resistant particles. The invention can be used to form edges, square panels and panels with more than four long and / or short edges. Definition of some terms
[003] In the following text, the visible surface of the installed floor panel is called "front side", while the opposite side of the floor panel faces the subfloor "rear side". "Horizontal plane" refers to a plane, which is parallel to the front side. Directly adjacent to the upper parts of two neighboring hinge edges of two floor panels joined together, it defines a "vertical plane" perpendicular to the horizontal plane. The outer parts of the floor panel at the edge of the floor panel between the front and the rear side are called the "hinge edge". As a rule, the hinge edge has several "hinge surfaces" that can be vertical, horizontal, angular, rounded, chamfered, etc. These articulation surfaces exist in different materials, for example, laminate, fiber board, wood, plastic, metal (in particular aluminum) or sealing materials.
[004] By "locking" or "locking system" we mean means of connection in a cooperative way that interconnect the floor panels vertically and / or horizontally. By "mechanical locking system" is meant that locking can take place without glue. Mechanical locking systems can in many cases be joined by glue.
[005] By "vertical locking" we mean locking parallel to the vertical plane and by "horizontal locking" we mean locking parallel to the horizontal plane.
[006] By "vertical locking surfaces" we mean the upper and lower cooperative tongue surfaces on the tongue on a first cooperative edge with upper and lower cooperative tongue groove surfaces on the tongue groove on a second adjacent edge that locks adjacent edges in the vertical direction.
[007] By "horizontal locking surfaces" we mean an essentially vertical top groove edge and a locking element on the second cooperative edge with an essentially vertical top tongue edge and a locking groove on the first adjacent edge, the cooperative horizontal locking surfaces lock the adjacent edges in the horizontal direction.
[008] By "locking groove side" we mean the side of the floor panel where part of the horizontal locking consists of a locking groove whose opening is towards the rear side. By "locking element side" we mean the side of the floor panel where part of the horizontal locking consists of a locking element, which cooperates with the locking groove.
[009] By "locking angle" we mean the angle of the locking surfaces of the horizontal lock in relation to the horizontal plane. In cases where the locking surfaces are curved, the locking angle is the tangent to the curve with the greatest angle.
[0010] By "tool angle" is meant the angle of the plane in which a tool rotates.
[0011] By "decorative surface layer" we mean a surface layer, which is mainly intended to give the floor its decorative appearance. "Wear-resistant surface layer" refers to a highly abrasive surface layer, which is mainly adapted to improve the durability of the front side. In conclusion, a "decorative wear resistant surface layer" is a layer, which is designed to give the floor its decorative appearance as well as to improve the durability of the front side. The surface layer is applied to the core.
[0012] A "surface layer crest" refers to the part of the surface layer on the floor panel portions near the hinge edge, the portion of the surface layer running along the hinge edge. Background of the invention, Background technology and Problems thereof.
[0013] To facilitate the understanding and description of the present invention as well as the knowledge of the problems behind the invention, here follows a description of both the basic construction and function of floor panels with reference to Figures 1 to 6 in the attached drawings. This basic construction and function is also used completely or in part in the present invention.
[0014] A mechanical locking system comprises a tongue and a tongue groove for vertical locking and a locking element and a locking groove for horizontal locking. It has at least four pairs of active cooperative locking surfaces, two pairs for vertical locking and two pairs for horizontal locking. The locking system comprises several other surfaces, which are generally not in contact with each other and can then be produced with considerably greater tolerance than cooperative locking surfaces.
[0015] Laminate floors are usually composed of a core consisting of a 6 to 9 mm fiber board, a top surface layer with a thickness of 0.20 mm and a bottom balance layer. The surface layer provides appearance and durability to the floor panels. The core provides stability and the balance layer maintains the level of the plate when the relative humidity (RH) varies throughout the year.
[0016] Mechanical locking systems are generally formed by machining the plate core. Such machining needs to be very precise to guarantee high quality. It is especially important that the interlocking surfaces of horizontal and vertical cooperatives are formed with high precision to ensure easy installation and precise adaptation between adjacent edges.
[0017] Figure 1a illustrates, according to the prior art, a mechanical locking system (strap lock), which can be locked with an angle and which is widely used in the market. Such a locking system can also be designed to be locked with a vertical or horizontal slot. A vertical cross section of the floor panel is shown from a part of a long side 4a of the floor panel 1 ', as well as a part of a long side 4b from an adjacent floor panel 1. The bodies of the floor panels 1, 1 'can be composed of a fiberboard body or core 30, which supports here, a decorative and wear-resistant surface layer 31 on its front side and a balancing layer 32 on its side rear (bottom side). The locking system has a tongue 10 and a tongue groove 9 which locks the panels in a vertical direction D1 with the upper tongue 53 and lower 56 surfaces cooperating with the upper tongue 43 and lower 46 groove surfaces. A strip 6 is formed from the body and the balancing layer of the floor panel and supports a locking element 8 on one side of the locking element 1. Therefore, the strip 6 and the locking element 8 form an extension of the lower part of the tongue groove 46. The locking element 8 formed in the strip 6 has an operating surface of the locking element 11 which cooperates with a operating surface of the locking groove 12 in a locking groove 14 on the opposite side of the locking groove of the adjacent floor panel 1 '. By engaging between the horizontal locking operating surfaces 11, 12 a horizontal locking of the floor panels 1, 1 'across the hinge edge (direction D2) is obtained if the panels are spaced apart. The locking angle A of the locking surfaces 11, 12 is 90 degrees in this mode shown and this provides a very strong horizontal lock. Locking systems are also formed with other locking angles, for example, 45 to 60 degrees. Some locking systems have a very low locking angle, for example, 30 degrees. Low locking angles make it possible to produce compact locking systems and save material. However, the locking force of such systems is very low. The upper part of the locking element side 1 comprises a first upper edge 19 and the upper part of the locking groove side 1 'comprises a second upper edge 18 which prevent horizontal movement if the panels are pressed against each other.
[0018] Figure 1b shows a laminated surface layer, which consists of a transparent coating 33 with wear-resistant particles of aluminoxide 36, and a decorative paper layer 35 with an engraving 34 that gives the surface its decorative properties. The engraving, which in most cases is a wooden design, usually has a white base layer, which is not visible on a floor panel with top straight and vertical edges. Some floor panels are formed with decorative chamfers 31a, which are covered with paint or decorative tape. It is also known that a part of the coating 31b can be machined as a small chamfer to make the edge softer and to remove edge burrs that can occur if the tools are not sharp. Such machining of the coating is carried out as a final step after machining the surface layer and the upper edge with processes similar to sanding operations.
[0019] A locking system (tongue lock) can also be formed without a strip 6 as shown in Figure 2a. The locking element 8 in this embodiment is located on the tongue 10 and the locking groove 14 is formed as a groove notched in the tongue groove 9.
[0020] A locking system can also be formed with a flexible tongue 10a (fold lock), which can be moved during locking. Such a locking system, as shown in Figure 2b, can be locked with a vertical movement D1.
[0021] A locking system (hook lock) can also be formed without a tongue, as shown in Figure 2c, to lock only in the horizontal direction D2. Such a locking system is used on the short sides of narrow floor panels. Vertical locking is performed with the long sides of adjacent panels.
[0022] All of these known locking systems, which are used to lock panels horizontally, have two cooperating surface pairs 18, 19 and 11, 12, which must overlap each other in a precise manner in order to function properly.
[0023] Figures 3a (side view) and 3b (top view) illustrate the most used method to produce a locking system and the main problems related to such production. The locking system is formed with the surface 31 of the floor panel pointing downwards. Various rotary tool configurations 60 are used to profile the edges when a floor panel 1, 1 'is moved horizontally in a linear feed direction by a chain 70. A belt 70a supported by pressure wheels 70b is used to produce a pressure vertical against the current. The belt has no stability in the horizontal direction D2 perpendicular to the feed direction. The vertical position D1 and horizontal D2 of the floor panel is obtained by the chain, which moves with high precision in relation to the rotary tool configuration. The superficial layer of the floor panel is fixed to the chain with friction.
[0024] Figure 4a shows a floor panel, which is produced with profiling equipment comprising a chain 70, and a belt 70a supported by pressure wheels 70b produces vertical pressure against the chain. Figure 4b shows that perfect machining can form very precise grooves 14, locking elements 8 and upper edges 18, 19, which in theory are almost completely parallel. Production tolerances can be as low as + - 0.02 mm. In practice, however, it is very difficult to achieve such tolerances. The reason is that the friction between the chain and the floor surface is not sufficient and the floor panel moves or rotates horizontally and perpendicularly to the feed direction during production (hereinafter referred to as horizontal rotation). The belt, the chains, especially if they are not parallel, the pressure tools and shoes, which are also used (not shown), produce uncontrolled horizontal lateral pressures against the floor panel and the parts mentioned above of the locking system do not will be formed completely parallel as shown in Figure 4c. The distances L1, L2 between the top of the floor panel 18, 19 and the locking surfaces 11, 12 on a part of the panel can, for example, be 0.1 to 0.2 mm less than the corresponding distances L3, L4 in another part of the same panel. The lock can be to tighten or to loosen. The tongue 10 and the tongue groove 9 can also vary in the horizontal direction. Such tolerances 10 ', 9' as shown in Figure 1a do not cause any problems, however, since the locking system is formed with spaces between the tip of the tongue and the inner part of the groove and such spaces are used to compensate for the tolerances of mentioned above.
[0025] Several methods were used to solve problems related to horizontal rotation. The most used methods are to make the profiling equipment more stable with improved chain orientation. Cleaning devices are also used to clean the chain to maintain high friction between the chain and the floor panel. The special GD guidance devices as shown in Figure 4a, as verification guides, which cooperate with special grooves on the rear side of the panel, were used to prevent horizontal rotation. Such guides and grooves are difficult to adjust, they cause wear and heat during production and can produce stability problems when a balance layer is separated by a groove.
[0026] All these efforts to improve the profiling equipment, however, have not solved the problems. On the contrary, the problems of horizontal movement have increased over the years. One reason is that the production speed has increased and this creates stronger lateral pressure. Floor panels with smaller sizes, deep embossing and glossy surfaces have been developed and this reduces the friction between the chain and the floor surface and increases the risk of considerable uncontrolled horizontal swing.
[0027] Other methods, which have also been introduced, are based on the principle of using tool positions and tool design to decrease horizontal rotation. This is shown in Figures 5 and 6.
[0028] Figures 5a to 5e show traditional tool solutions for producing floor panels with a wear resistant top surface layer. The floor panel is moving in the FD feed direction of the arrow when profiling the edges. The first step in the profiling line is illustrated in figure 5a and the last step in figure 5e. The cross section of the floor panel 1, 1 'is shown positioned with and top surface layer 31 down in a ball bearing chain 70 on a milling machine. A traditional machining facility drives frame 1, 1 'with optimum accuracy across a number of rotary cutting tool configurations independently. The cutting tools generally have a tool diameter of approximately 200 to 250 mm and can be adjusted at an optional tool angle TA to the horizontal plane HP of the frame. The tools are mounted on opposite sides of several columns. The distance between the TD tools is about 0.5 m and the distance between the CD columns is about 1 m as shown in Figures 3a and 3b. Each tool 60 to 64, 60 'to 63' is dedicated to removing a limited portion of the hinge edge, where some also form from the final hinge surfaces. Several tools are positioned along both sides of the profiling line in the FD feed direction of the floor panel 1, 1 '. This is done in order to obtain sufficient production tolerances. A general rule of thumb is that an increase in the number of tools results in increased production tolerances since each tool removes less material and creates smaller forces that can displace the floor panel in an uncontrolled manner. The normal production mode should use 4 to 6 opposing tool pairs on a first machine that cuts the long side, followed by a similar machine that cuts the short side locking system on the panel.
[0029] The horizontal locking surfaces 18, 19, 11, 12 are machined with four independent tools 62, 62 'and 63, 63'. A horizontal rotation between the third (FIGURE 5c) and the fourth (FIGURE 5d) tool station on each side will create horizontal locking surfaces 18, 19, 11, 12 that are not parallel as shown in FIGURE 4c.
[0030] Traditionally, when producing mechanical locking systems on a floor panel, coarse cutting tools 60, 60 ', as illustrated in FIGURE 5a or the fine cutting tools 62, 62', as illustrated in FIGURE 5c, are positioned in an independent profiling position on one side of the FD feed direction of the floor panel 1, 1 'and on the opposite side as opposite pairs. One tool in the pair is machining the locking groove side 1 and the other tool is machining the locking element side 1 '. Coarse cutting tools 60, 60 'remove most of the highly abrasive material from the wear-resistant surface layer in order to increase the service life and cut quality of the next tools, with the exception of tool 62, 62 'which also cut into the wear-resistant surface layer. The cutting edges of the tools consist of diamond, but even so, the tool's operating time is limited, usually no more than 5,000 to 20,000 meters when cutting in a highly abrasive top layer. Because of this, the tools that cut the surface layer, the coarse cutting tools 60, 60 ', as illustrated in FIGURE 5a and the fine cutting tools 62, 62', as illustrated in FIGURE 5c are configured with a cutting edge. straight cut that can be moved step by step M parallel to the cutting edge during production to bring a new tool cutting edge into a cutting position.
[0031] Such horizontal rotation with a horizontal tool angle TA and a vertical adjustment step by step M is shown in Figures 6a to 6c. FIGURE 6a shows the deburring surface 71 of the fine cutting tool 62 that forms the top surface layer 31 of the floor panel 1. If the frame has a wear resistant top surface layer the fine cutting tool it is worn much faster compared to cutting at the core of the board, for example, high density fiber board (HDF). The result is a worn portion of the cutting surface 72 as shown in FIGURE 6b on tool 62, which results in the so-called burring of the top edge portion of panel 73, that is, small cracks occur and the edge becomes thick and small white portions of the print base layer may appear. FIGURE 6c illustrates how the fine cutter 62 is moved in small steps in the vertical direction M a few tenths of a millimeter, so that a new cut portion 71 of tool 62 is in position against the top surface 31. A similar principle it is used for coarse cutters and the step-by-step movement of the tools is done while the machine is running in order not to lose the running time on the line.
[0032] Coarse cutting tools 60, 60 'in FIGURE 5a are generally positioned with an ED distance of approximately 0.5 mm from the vertical plane VP and the upper end edge 18, 19. All next cutting tools, except the fine cutter 2, 62 'are all designed in such a way that their cutting teeth will maintain a safe distance from the surface layer at the top edge in order to avoid the risk of cutting in the wear-resistant surface layer 31 and thereby prevent them from wearing out quickly, especially since these tools cannot be moved step by step.
[0033] The horizontal rotation inside the profiling machine is to a large extent related to the fact that the tools create uncontrolled lateral pressures on the panels. Such lateral pressures can occur if the tools work with different tool angles, different rotations (with or against the feed direction) or if they remove different amounts of material or material with different composition (core, surface layer).
[0034] Tables 1, 1 'are generally more unstable and the horizontal rotation laugh is high in the first and last cutting positions, relative to other cutting positions due to several reasons. For example, the frame is only attached by the chain and the belt for a limited length and the input / output equipment can push the edges slightly.
[0035] The machining of cooperative horizontal locking surfaces 11, 12, 18, 19 is therefore generally positioned in the internal tool positions together with one another. These are formed by the fine cutters 62, 62 'in FIGURE 5c and locking groove cutter 63', locking element cutter 63 in FIGURE 5d. The fine cutters 62, 62 'in FIGURE 5c are generally always positioned after the tools that form the tongue and the tongue groove as shown in FIGURE 5b. This is a major advantage since most of the material is already removed by the previous tools 60, 60 ', 61, 61' when the fine cutters start to remove material. Fine cutters 62, 62 'should only remove a very limited amount of the core material and the last part of the wear-resistant surface layer 31. This makes it possible to obtain tight machining tolerances, reducing cutting forces and horizontal pressure on the floor panel.
[0036] The thick cutters 60, 60 'and the thin cutters 62, 62' are, as described above, always separated with different tool positions in the middle. This causes a substantial uncontrolled horizontal rotation between the thick cutters 60, 60 'and the thin cutters 62, 62' and such a rotation can be about 0.2 mm. Thick cutters should then be positioned at a safe distance, generally at least 0.5 mm, from the final surface edge, in order to avoid quality problems such as chipped edges, visible white lines of paper. decoration on core display.
[0037] The locking surfaces of the locking groove 14 and locking element 8 are formed with the rotary tool configuration 63, 63 'having a tool angle TA equal to or greater than the locking angle LA. A rotary tool configuration that forms a locking surface with a locking angle A can never work with a tool angle TA that is less than the locking angle A. This is a considerable limitation, which should be considered in the design and production of locking systems.
[0038] The horizontal and vertical locking tools 61, 61 ', 63, 63' in FIGURE 5b and 5d are all examples of rotary tool configurations that consist of two relative to each other adjustable tool bodies TB1 and TB2 mounted on the same rod. Such tools are hereinafter referred to as COMBI tools. These COMBI tools are necessary when the tool forms a geometry, for example, a groove, which consists of two opposite cutting surfaces with a fixed relative distance from each other. When the tool is sharpened, then some material from the tool is removed and a relative distance between the opposite edges is changed. The two bodies can then be adjusted in one dimension over size and then crushed to the correct relative dimension. A positive effect of these COMBI tools is that the precision between the two profiled surfaces formed by the two tool bodies is very accurate since it is profiled in the same position and with the same tool. Such COMBI tools 61, 61 'can be used to improve tolerances between a pair of the vertical locking surfaces of the tongue, as shown in FIGURE 5b. COMBI tools are not, however, used to produce a pair of horizontal locking surfaces.
[0039] One reason is that the top edge on the side of the locking groove must be formed with a tool body 62 'that has a tool angle that is different from the tool angle of the tool body 63' that forms the surface of locking in the locking groove as shown in FIGURES 5c and 5d. The tool bodies of a COMBI tool are always working with the same tool angle as they are attached to the same shank. Another reason is the fact that one of the tool bodies 62, which forms the upper edge, must work horizontally and must be vertically adjustable gradually. A COMBI 63, 63 'tool cannot be adjusted vertically in a gradual way as such adjustment at the same time changes the position of the other tool body TB1 and TB2, which is used to form the locking surface of the locking element. A COMBI tool with two tool bodies on the same shank has two main limitations. Both tool bodies TB1, TB2 must work with the same tool angle and must be moved in the same direction at the same time.
[0040] The main challenge while machining a mechanical locking system, apart from the general production cost, is to obtain sufficient production tolerances, that is, to achieve an appropriate joint geometry and to do this in a cost efficient production mode. Thus, it would be highly desirable in the manufacture of floor panels to reduce horizontal locking tolerances even further to a considerably lower level and in an easy, cost-effective manner. Summary of the Invention and Objectives
[0041] The main objective of this invention is to provide solutions to problems related to the horizontal rotation of floor panels during the machining of a mechanical locking system and especially during machining parts of the mechanical locking system, which are used to obtain horizontal locking.
[0042] A specific objective is to neutralize or eliminate horizontal rotation and / or to reduce the negative effects of such horizontal rotation during the production of floor panels, especially in floor panels that have a wear-resistant top surface layer similar to laminate flooring.
[0043] Another objective of an exemplary embodiment of the invention is to keep the production cost low with improved tool uptime as the low time on the profiling line is decreased due to less tool changes.
[0044] The objective was achieved and the problem was solved with a first principle that is based on a production method in which the tools that form horizontal locking surfaces are combined with a tool configuration on the same side of a column that has two opposite column sides. This can eliminate substantially any horizontal rotation between tools in the tool configuration. This type of machining, however, creates high wear on the tool that forms the wear-resistant surface layer and it is not possible to increase the tool's service life with a gradual adjustment during production. Thus, a pre-processing step is introduced by pre-processing at least a part of the wear-resistant top surface layer of the floor panel on the first top edge so that the properties of the surface layer are changed.
[0045] The problem was solved with a second principle in which the tool set combined at least on the side of the locking element is a rotary tool configuration in which the same tool shank is driven by at least two tool bodies, which can be individually adjusted in relation to each other. Such a rotary tool configuration can only work with a substantially vertical vertical tool angle or at least with a tool angle that is equal to or greater than the locking angle of the locking surface. This type of machining, however, creates high wear on the tool that forms the wear-resistant surface layer and it is not possible to increase the tool's service life with a gradual adjustment during production. Instead of the processing step being introduced by changing the properties of the surface layer.
[0046] The problem was then solved with a third principle in which an intermediate pre-processing step of the surface layer is done before the formation of the horizontal locking surfaces. Such intermediate pre-processing that removes material or changes material properties, can be done with several methods and even with traditional thick cutters, which are positioned very close to the final edge of the top surface layer and in a position close to the cutters. thin. The intermediate pre-processing is, however, preferably done so that a ridge defined as a part of the wear-resistant surface layer that belongs to the vertical and inward plane, is removed. This special type of intermediate pre-processing makes it possible to avoid high wear in a rotary tool configuration that works essentially vertically and to avoid horizontal rotation between the intermediate pre-processing tool and the rotary tool configuration.
[0047] All three of these principles can be used independently in order to improve the machining of mechanical locking systems. The best result is achieved, however, if they are combined.
[0048] According to a first aspect of the invention, a method for producing mechanical locking systems at opposite edges of a floor panel is provided with the use of a first tool configuration on a first edge. The floor panel has a wear-resistant top surface layer, a core and mechanical locking systems on the first and second edges for horizontal locking of the panel with other similar panels. The mechanical locking system comprises a first pair of locking surfaces on the first edge of a panel and a second pair of locking surfaces on the second opposite edge. The first pair of locking surfaces comprises a first upper edge and a locking element. The second pair of locking surfaces comprises a second upper edge and a locking groove. The floor panel is arranged in a feed direction with its first edge relative to the first tool configuration. The first tool configuration comprises a first and second tool body positioned on the same side of a column that has two opposite column sides. The method comprises the step of: - Pre-processing at least a part of the wear-resistant top surface layer of the floor panel on the first top edge so that the properties of the surface layer are changed. - Form through the first and second tool bodies at least part of the first pair of locking surfaces.
[0049] This method essentially provides improved tolerances on the locking groove side due to the use of a tool configuration with the two tool bodies on the same side of a column. Further improvements can be obtained if the locking groove side, or at least one of the locking surface pairs on the groove side, is also formed simultaneously by the same type of tool on the opposite side of the panel.
[0050] An exemplary embodiment of the first aspect therefore provides a method for producing mechanical locking systems on opposite edges of a floor panel using a first tool configuration on a first edge and a second tool configuration on a second opposite edge. The floor panel has a wear-resistant top surface layer, a core and mechanical locking systems on the first and second edges for horizontal locking of the panel with other similar panels. The mechanical locking system comprises a first pair of locking surfaces on the first edge and a second pair of locking surfaces on the second opposite edge. The first pair of locking surfaces comprises a first upper edge and a locking element. The second pair of locking surfaces comprises a second upper edge and a locking groove. The floor panel is arranged in a feed direction with the first edge of it relative to the first tool configuration and the second edge of it relative to the second tool configuration. The first and second tool configuration comprise a first and second tool bodies which are engaged with the floor panel on the same side of a column, with each column having two opposite column sides. The method comprises: - Forming by means of the second tool configuration at least a part of at least one of the surfaces of the second pair of locking surfaces. This can also be combined with the following step then performed before the forming step: - Pre-process at least a part of the wear-resistant top surface layer of the floor panel on the second top edge so that the properties of the layer surface are changed.
[0051] The first and second tool configurations should preferably be positioned essentially opposite each other transversely to the feed direction. Tool settings should preferably not be arranged along the feed direction more than the average distance between the columns on the same side of the chain. The best result is obtained, however, if the tool configurations are located completely opposite each other, perpendicular to the feed direction, which means that the formation of the locking surfaces of the first and second edges will begin and end at the same time.
[0052] This first aspect offers the advantages that a rotation of a floor panel during production will not alter the relative distance between the horizontal locking surfaces in cooperation for two reasons. Firstly, they are formed with the first and the second tool bodies, which are located on the same side of a column, close to each other, in the direction of feeding or, preferably, in the same position and this eliminates the rotation between tool bodies. Second, the first and second tool configurations are also located essentially opposite each other transversely to the feed direction and this eliminates the rotation between the tool configurations. The second pre-processing step, which is an intermediate pre-processing step and is carried out close to the first tool configuration and / or second tool configuration, makes it possible to use a rotary tool configuration with a considerable service life.
[0053] The horizontal rotation between the second pre-processing tool and the rotary tool configuration can be as small as 0.05 mm and below and this makes it possible to remove almost all wear-resistant layers without any quality problems since the second pre-processing tool can, for example, be used to remove 0.5 mm from the surface that remains after the first pre-processing tool. Such a tool can even remove a part of the coating within the vertical plane.
[0054] According to an exemplary embodiment of the first aspect, the method further comprises: - That the intermediate step remove a part of a crest from the wear resistant top surface layer.
[0055] Such pre-processing will considerably increase the service life of the rotary tool configuration. The service life can be essentially longer than for conventional tools using conventional production methods.
[0056] The ridge can be removed using a conventional rotary tool or a non-rotating scraping tool configuration, which comprises several teeth positioned along the feed direction in a tool body.
[0057] Production tolerances related to horizontal rotation can also be reduced if the first and / or the second pair of horizontal surfaces are formed with tool bodies that are positioned on one side of a column as close to each other as possible above or below each other or side by side. Tool bodies may comprise a combination of two rotary tool configurations, two scraping tool configurations or one rotating and one scraping tool configuration.
[0058] According to a second aspect of the invention, a tool configuration for producing mechanical locking system on a floor panel is used. The floor panel has a wear-resistant top surface layer, a core and mechanical locking system on a first and second edge for horizontal locking of the floor panel with other similar panels. In addition, the mechanical locking system comprises a first pair of locking surfaces on the first edge of a panel and a second pair of locking surfaces on the second opposite edge, the first pair of locking surfaces comprises a first upper edge and an element the second pair of locking surfaces comprises a second upper edge and a locking groove. The tool configuration comprises a first tool configuration, and the first tool configuration comprises a first and second tool body. The first tool configuration is positioned on the same side of a column that has two opposite column sides. The tool configuration has the means to pre-process at least a part of the wear-resistant top surface layer of the floor panel on the first top edge so that the properties of the surface layer are changed. The first and second tool body comprises means for forming at least a part of the first pair of locking surfaces. Horizontal rotation can also be canceled with an equipment and production method in which the lower chain is essentially used for the vertical orientation of the floor panel only. The horizontal orientation is contrary to the knowledge of methods performed by a belt or upper chain.
[0059] According to a third aspect of the invention, equipment for producing mechanical locking system on opposite edges of a floor panel is provided and comprises a lower chain, a belt or upper chain and various tool configurations to form the edges opposite. The floor panel is moved in a feed direction by the lower chain or the upper chain or chain with its decorative front side in contact with the lower chain. The lower chain is guided vertically and horizontally with a lower guide device. The upper belt or chain is guided in a horizontal direction by an upper guide device and configured so that it presses the floor panel vertically towards the lower chain. The guiding devices are configured so that a horizontal deviation from a feed direction immediately between the two tool configurations of the upper belt or chain is essentially the same or less than the corresponding lower chain deviation.
[0060] Several advantages can be achieved with production equipment where the horizontal orientation is essentially obtained by an upper chain or belt. The rear side of the floor panel, which is in contact with the belt or chain, can be formed with the surface, which can create high friction. The upper belt or chain may also have a high friction surface. Such a surface can also create some protrusion on the rear side without any negative effect on the quality of the floor panel. A very strong connection between the belt or upper chain and the floor panel can be obtained regardless of the surface structure of the decorative side, which is in contact with the lower chain. The equipment also offers the advantages that no additional guide grooves are required and that no separate adjustment of the guide parts is required if the panel size or locking system is changed.
[0061] The first, second and third aspects can be used independently or in combination to cancel or eliminate the horizontal rotation of the floor panel during production. Brief Description of the Drawings
[0062] Figures 1a to b show a cross section of a floor panel that illustrate a mechanical locking system close to a surface layer, known in the prior art.
[0063] Figures 2a to 2c illustrate different types of mechanical locking systems, known in the prior art.
[0064] Figures 3a to 3b show a side and a top view of a traditional profiling line to produce floor panels with a wear resistant top surface layer, known in the prior art.
[0065] Figures 4a to 4c show a cross section of a side view on the side of the short floor panel with traditional profiling equipment, as well as a complete top view and a side view of the short side of the floor panel after machining, known in the prior art.
[0066] Figures 5a to 5e are manufacturing steps to produce a mechanical locking system on a floor panel, known in the prior art.
[0067] Figures 6a to 6c show the cross section of a tool that cuts through the laminated layer, gradual illustrative movements to improve the tool's working time, known in the prior art.
[0068] Figures 7a to 7c are cross sections of manufacturing steps that incorporate an exemplary modality of how an improved locking system for mechanical locking of floor panels is manufactured, according to the invention.
[0069] Figures 8a to 8c are side and top views of parts of different profiling lines, which illustrate a side and top view of exemplary ways of configuring tool solutions as shown in Figures 7a to 7c, according to the invention.
[0070] Figures 9a to 9d are cross sections of exemplary modalities of the pre-processing steps, according to the invention.
[0071] Figures 10a to 10e are cross sections of manufacturing steps that incorporate an exemplary modality of how an improved locking system for mechanical locking of floor panels is manufactured, according to the invention.
[0072] Figures 11a to 11c is a top side view of the complete floor panel produced by an exemplary embodiment of an improved manufacturing step, according to the invention.
[0073] Figures 12a to 12e are side views of a cross section of the groove side of a floor panel that explains the mechanism behind the COMBI configuration tool solution and side views of a cross section that explain the direction of turning the COMBI configuration tool solution according to the invention.
[0074] Figures 13a to 13b are a top and side view of an exemplary embodiment of a configuration tool solution that incorporates a pre-processing step, according to the invention.
[0075] Figures 14a to 14d are cross sections of a side view of exemplary configurations of solution of configurations tool, according to the invention.
[0076] Figures 15a to 15c show a cross section of a side view of an exemplary embodiment of a pre-processing step, according to the invention.
[0077] Figures 16a to 16d are cross-sections of a side view of different designs of mechanical locking systems currently possible to produce with the exemplary configurations of solution of configuration tools, according to the invention.
[0078] Figures 17a to 17e are cross sections of manufacturing steps that incorporate an exemplary modality of how an improved locking system for mechanical locking of floor panels is manufactured, according to the invention.
[0079] Figures 18a to 18b are side views of exemplary modalities of a solution for tool installation, alternatives to the COMBI tool and which incorporate a pre-processing step, according to the invention.
[0080] Figures 19a to 19c are cross sections of exemplary modalities of COMBI tools and their cutting surfaces, according to the invention.
[0081] Figures 20a to 20f are cross sections of exemplary modalities of a COMBI tool and how it can vary in position, according to the invention.
[0082] Figures 21a to 21b are a cross section of a side view of the short side of the floor panel with exemplary modalities of an equipment for producing improved mechanical locking systems on opposite edges of a floor panel.
[0083] Figures 22a to 22b are a cross section of a side view of the short side of the floor panel with exemplary modalities of an equipment for the production of mechanical locking systems on opposite edges of a floor panel.
[0084] Figures 23a to 23b is an exemplary embodiment of a scraping tool configuration, an alternative to the COMBI tool, according to the invention. Detailed Description of Modalities
[0085] Figures 7a to 7c are a profiling line that illustrates exemplary modalities of solutions for installing a tool for producing improved mechanical locking systems in a floor panel, according to the invention. The horizontal locking surfaces on the locking element side 1 are pre-processed in a first step with a pre-cutter 60 that removes most of the core and surface adjacent to the vertical plane VP as shown in Figure 7a. In conventional profiling, it is normal to position the pre-cutter 60 with an ED distance of approximately 0.5 mm from the vertical plane VP. Figure 7b is a solution for tool installation of an intermediate pre-processing step, according to an exemplary modality that can be incorporated in the profiling line of the invention, the step in which at least most of the resistant surface layer the wear that remains after the first pre-processing step, see Figure 7a, is removed. Such formation is very precise and can be done with very little force since a very small amount of material is removed, and the intermediate pre-processing tool configuration can be positioned very close to the next tool, which forms the locking surfaces. . For tool maintenance, the pre-cutter 60, 60 'and the intermediate pre-processing tool configuration 67 can be moved step by step in a direction M parallel to the cutting edge, and this increases the tool life considerably. Figure 7c is a solution for installing a one-stage tool, according to an exemplary modality that can be incorporated into the profiling line of the invention. The horizontal locking surfaces on the side of the locking element 1 are formed with a rotary tool configuration, that is, a COMBI tool comprising two tool bodies. In tool installation 68 a first tool body TB1 forming the first top edge 19 and a second tool body TB2 forming the locking element 8 of the floor panel 1. This ensures that the intermediate position of the locking surfaces will always be correct regardless of a horizontal rotation of the panel during production. In this mode, the COMBI tool has a tool angle of 90 degrees TA against the floor surface and forms a locking surface on the side of the locking element 1, which has a locking angle of 90 degrees LA (see also from Figure 20a to 20c). The COMBI tool cannot be moved step by step. The lifetime of the first TB1 tool body can, however, be as long or even considerably longer than for conventional tool installation solutions, due to the fact that only a very small part of the surface layer finally remains after application. intermediate pre-processing step must be removed.
[0086] Figure 7c shows that a second tool configuration 68 'comprising a first tool body TB1 and a second tool body TB2 located vertically over each other on the same column can preferably be used to form the horizontal locking surfaces on the locking groove side 1 '. An intermediate pre-processing step is not necessary at this point as the TB1 fine cutter can be moved vertically step by step. It is, however, an advantage to use an intermediate pre-processing step in order to increase the life span of the additional fine cutter TB1 ', for example, the same as illustrated for the locking element side 1, in Figure 7b.
[0087] Figures 8a to 8c are different views of a profiling line that illustrates exemplary modalities of solutions for tool installation of Figures 7a to 7c for producing improved mechanical locking systems on a floor panel, according to the invention . Figure 8a is a side view of the locking element side 1. The intermediate pre-processing tool configuration 67 is positioned on a first column 81 and the COMBI 68 tool on an adjacent side of a second column 80. This results in tools are too close to each other and horizontal turns may be limited or non-existent. The TD tool distance measured from one shank center to the other shank center can be less than the diameter of the largest tool for the best result in limiting horizontal rotation. This is equivalent to a TD distance of less than 240 mm with traditional tools used today, compared to the commonly used TD distance of 400 to 500 mm in today's profiling machines. The TD tool distance can be even shorter if the tools are partially overlapping each other vertically. Figure 8b is a side view of the locking groove side 1 '. It shows a first TB1 and a second TB2 tool body that forms the top edge and the locking surface of the locking groove. The tool bodies are positioned vertically on top of each other. This results in the horizontal rotation that does not change the relative distance between the pair of horizontal locking surfaces, see Figures 11 a through c. Figure 8c is a top view of the profiling line and shows that the high quality horizontal locking surfaces can be formed with four rotary tool configurations positioned on three columns: a second column 80, a third column 80 'and the first column 81 and on three column sides. It is an advantage if the two tool configurations 68, 68 'that form horizontal locking surfaces 11 and 19, 12 and 18 are located on each side of the chain opposite each other, aligned essentially along an LP line perpendicular to the direction of food. The formation of the cooperation interlocking surfaces will start and end in such a tool configuration at the same time and the effects of horizontal rotation on the relative position of the horizontal cooperation surfaces can be completely eliminated.
[0088] Figures 9a to 9d show exemplary modalities of the pre-processing step, as well as the intermediate pre-processing step, according to the invention. Heat, as a embodiment of FIGURE 9a, will affect the properties of the surface layer, such that they are altered, for example, to soften the wear-resistant top surface layer. When highly abrasive particles, for example, aluminum oxide, are not well fixed in a matrix, heating the wear-resistant top surface layer will reduce the wear resistance of the top surface layer. Heat can, for example, be introduced with IR (Infrared Radiation), just before the final profiling of the joint surfaces, which are collected at a tool station, on the profiling machine or even before the profiling line starts on the machine. . The laser, as another modality, can also be used as a heating medium as long as it is efficient and can access the surface layer extremely close to the fine cutter. The heating can, for example, be done with in addition to the laser, infrared lamps or hot air, with other methods, as a person skilled in the art will appreciate, as a hot slide shoe, microwave and other heating technologies or a combination of the same. The use of laser only for the purpose of heating instead of cutting will also guarantee a very precise wear reduction, through which the life span of the fine cutter will become longer. Another exemplary embodiment of an alternative pre-processing step according to the invention is to add a lubricant, for example, wax to at least parts of the top surface layer of the floor panel. This will also change the properties of the surface layer. Heating or lubrication will be carried out essentially on a part of a wear resistant top surface crest. Figure 9b shows an additional exemplary embodiment of an alternative pre-processing step, according to the invention. A part of the decorative wear-resistant top surface layer 31 is removed with a scraping tool and this results in the fact that the properties of the surface layer are completely altered. FIGURE 9c shows a pre-processing step with a pre-processing tool configuration 67 that is positioned essentially in the vertical VP plane, see also FIGURE 1 b. FIGURE 9d shows a pre-processing tool configuration 67, which is positioned so that it removes a part of the wear-resistant layer within the vertical plane VP and forms a ridge 76 in the surface layer 31.
[0089] FIGURES 10a to 10e are a profiling line that illustrates exemplary modalities of tool installation solutions for the production of improved mechanical locking systems on a floor panel, incorporating an intermediate pre-processing step in the profiling line , on both opposite edges, according to the invention. An improved profiling accuracy for the mechanical locking system on the floor panel is obtained both on the side of the locking element and on the side of the locking groove and also a longer service life for the tools used in profiling them. FIGURES 10a to 10b correspond to FIGURES 5a to 5b and, therefore, are not described further. FIGURE 10c shows a tool installation solution, where intermediate pre-processing is done with intermediate pre-processing tool configurations 67, 67 'on the side of the locking element 1 and on the side of the locking groove 1'. FIGURE 10d shows a COMBI tool 68 on the side of the locking element 1 and a second tool configuration 68 'with a first TB1 and second TB2 tool body on the locking groove side 1'. For example, the locking surface and a part of the locking groove are formed by the second tool body TB2 in order to minimize the amount of material that is removed. This will increase the life of the tool. This second TB2 tool body can also be designed as a preferably simple scraping tool, which can be positioned on the same column side and above a first TB1 rotating tool body. The remainder of the locking groove, where strong tolerances are not required, can be formed by another tool 63 'as shown in FIGURE 10e.
[0090] The tool installation solution with a pre-processing step and COMBI tool that operate mainly in the vertical plane, according to an exemplary embodiment of the invention, can provide an extra ordinary tool life. Whereas a fine cutter in the prior art without preprocessing would operate approximately 10,000 to 20,000 meters of operation before the tool needs to be moved step by step, the tool configuration 68, 68 'can operate above 500,000 meters of operation before the tool needs to be sharpened again. This, in turn, provides a substantial benefit in reduced time on the profiling line due to tool changes and also a notable effect on the risk of the operator failing while re-equipping the new tool. There are more positive effects than tool life when cutting in the vertical plane. The operation of the traditional fine cutter on the horizontal plane will create a ripple on the vertical contact surface 18, 19, in FIGURE 1. This is a well-known phenomenon, which, for example, is described in the prior art documents WO 2006117229A1 or EP 1851020A1. The fine cutter mentioned above will solve this problem as long as the cutting of the edges of the teeth moves completely along the vertical plane parallel to the contact surface 18, 19 in FIGURE 1, by means of which no cutting waves can occur. This technology will be much more cost effective than, for example, alternative laser technology.
[0091] FIGURE 11a shows that the production methods described above according to the invention will make it possible to form horizontal locking surfaces on opposite sides that are positioned at the same relative horizontal distance L1, L2, L3 and L4 to each other throughout the length of the floor panel, even in the case when a substantial horizontal turn occurs. A turn of, for example, 0.2 mm will be present in the tongue 10 and in the groove of the tongue 9, but this will not influence the locking quality as explained previously. The horizontal loop will change the shape of the upper edges, so that they will not be completely perpendicular to the shorter edges 5a, 5b. This deviation will disappear when the shorter edges are formed, provided that the upper edge is usually used as a basis for the thrusters that are used in the short edge tillering. This type of tolerance can be easily eliminated even in the case where the horizontal loop results in a curved shape of the horizontal locking surfaces, as long as the intermediate distance L is the same. Part of the tolerances will be removed when machining the short edge. The remaining tolerances of, for example, 0.1 mm will result in a banana shape that can be easily arranged automatically during installation, as long as the locking element and locking groove are formed with rounded guide surfaces that automatically press the panels of floor joining them and forming a straight line. The panels can, of course, also be pressed together smoothly. All panels have a smooth banana shape even in the case and perfect machining is carried out. FIGURE 11c shows that the tool installation solution as shown in FIGURE 10d according to an exemplary embodiment of the invention can be designed so that the tongue strip and the outside of the strip are formed by, for example, a third body of tool TB3 or part of a tooth 68a of the tool COMBI 68. Such machining will also eliminate the effects of the horizontal turn in the vertical locking medium if necessary. This tool configuration can be used to form locking systems with adjacent surfaces, which have a precise fit and no space is required to compensate for production tolerances. This makes it possible to form locking systems resistant to moisture and adjustment.
[0092] Figures 12a to 12e show the direction of the cutting forces that explain the mechanism behind the COMBI 68 system installation configuration as shown in Figures 7c, 8a or 10d. A fine cutter from the prior art directs cutting forces in the Py, Px and Py directions, shown in Figure 12a. The Py force has a clear risk of creating micro burrs as described above, since the outward-directed force creates tension in the brittle surface layer that has no support behind it. Figure 12b shows an exemplary embodiment of the system installation solution of the forming step, according to the invention, the disc 96 of the fine cutting tool 68, operates mainly in the vertical plane and rotates in the feed direction of the frame, ie the operating teeth move in the same direction as the frame, the FD feed direction. Because of this, there will be no Px or Py forces that create micro burrs from the surface layer. Tool 68 can therefore be less sharp than what would be required if there is a Py force on the surface layer. If tool 68 were to operate in the opposite direction, this could result in a significant Py force created which would consequently reduce the tool speed and tool life drastically.
[0093] A second mechanism that increases the service life of the specific system installation solution 68, in Figure 12b, is the wear characteristics of the tool tip 92 of the tool body 96 of the fine cutter in Figure 12c. The outer tip part Cc of tool 68 will be the part to hit the highly abrasive surface layer first and remove the material. The other cutting edge Dd positioned before Cc will now cut only at the core 30. However when the tool tip Cc is worn, it will be slightly spaced from the edge 18, 19, in Figure 1, and through this the new part of the cutting edge the tip Cc will then cut into the highly abrasive surface layer. When that part is worn out, then a new part of the new cutting edge will cut and the tool will gradually wear away from the tip of the tongue until the tip is worn out to the Ee part. One way to maximize tool life is therefore to increase the distance from the tool tip part Cc to Ee. Compared to the traditional fine cutter where it was necessary to manually move the tool from end to end, this operating mode that works in the vertical plane with the tool will automatically position a new cutting edge on the highly abrasive material as soon as it becomes worn.
[0094] The direction of rotation of the rotary tool configuration 68 'must be against the feed direction FD in the locking element on the V side, when using the same principles as the COMBI 68 tool, in Figure 12b, on the groove side locking 1. This rotating direction ensures that the cutting forces are directed inward into the surface layer in the core, which is very important, as described above. Two exemplary embodiments are shown in Figures 12d and 12e, showing a higher locking angle in horizontal locking where a higher tool angle is needed. It is even possible to use this method with a locking angle of 90 degrees for horizontal locking, if there is no tongue protruding from the locking system of Figure 12e.
[0095] If the rotary fine cut part 96 in Figure 12b would not operate completely in the vertical plane but slightly angled thereby changing the tool wear mechanisms of the fine cut tool. This, in return, can have a positive effect on tool life on certain materials, for example, very brittle surfaces, which are very sensitive to tool sharpening. When rotating in the pure vertical plane without angulation, the sharpest outer part of the tongue tip, between CC and Ee in Figure 12c, will remove the highly abrasive surface layer. The movement of a tooth of the tool is illustrated in Figure 12d with a view from the top, when all removal of the surface layer will be performed in position A, when the tool is new. Part of the new edge tip will slide along the already cut crest layer of the edge of the surface between position A and C. When the tool becomes worn, point A will move closer to point B and finally end at that point when the tool is worn, as described above. The first point at which the tool will start to cut, when the tool is worn out, will still be point A. If the material is sensitive to wear of the cutting edge it can cause some micro burring, even if a new cutting edge part of the next one coming tooth will remove some of the edge. Figure 12e illustrates the movement of the teeth on the crest of the surface layer due to the angle of the tool. At an angle, the tool tooth will cut along the full edge of the tool edge part Cc of part Ee, Figure 12c, since the tooth will gradually move inward in the frame from point A to point B in the frame, Figure 12e, following the TL tool line. From point B to C you will no longer be in contact with the board.
[0096] If the thin rotary cutter 96 in Figure 12b would be replaced with a scraping tool configuration and, for example, combined with a rotating tool configuration 95 or a scraping tool configuration, then the scraping tool configuration 96 it should preferably work at an inclined angle to direct the forces into the nucleus.
[0097] If the rotary tool operates from the top, for example, on the side of the tongue, and thereby rotating the direction necessary to be against the feed direction FD in order to direct the forces in the direction Py.
[0098] Figures 13a to 13b show a side and top view of an exemplary embodiment of a profile line that incorporates a pre-processing step, according to the invention.
[0099] Figures 13a to 13b show the system installation solution 68 which has a second tool Aa, which forms at least part of the cooperating surfaces that lock the adjacent edges horizontally or on the locking element or on the groove side of locking. The exemplary system installation solution 68 is mounted on one side 89 of the second column 80, but operating on the other side 88 of the second column 80, that is in conjunction with the first tool Bb. As an example of a system installation it comprises a first rotary tool configuration and a second scraping tool configuration, or the rotary tool configuration can also be a scraping tool configuration, a laser, small end mill or any other tool that can remove material. Since wear is greatly reduced due to the pre-processing step, it can even be a profile tool body for both cooperating surfaces. As a person skilled in the art can see, it will still be preferable to make step-by-step movements on a part of the tool body, since the part of the fine cutting tool will cut in most cases it will cut small parts, in the highly abrasive surface layer until even if wear is reduced by the pre-processing step and can consequently wear out faster than the rest of the profile system installation on the core only. The second tool Aa can, for example, also be mounted on the first column 81, but which operates on the same side 88 as the second column 80, if the two columns are close together.
[00100] The locking element and locking groove side can use a slightly variant tool installation solution, but they are all based on the common principle of machining at least part of the cooperating surfaces that lock the adjacent edges horizontally on the profiling machine, according to an exemplary embodiment of the invention. Preferably also with the incorporation of the pre-processing principle. As will be observed by a person skilled in the art, the pre-processing principle according to the exemplary modalities of the invention, can also be used in the production of floor panels that do not have a wear resistant top surface layer, which extends the service life of the tool installation with a pre-processed operating surface for the tool installation.
[00101] Figures 14a to 14d show exemplary modalities of tool configurations according to the invention. Figure 14a shows that the second configuration tool 68 'forming the upper part 18 of the edge on the locking groove side 1' works vertically with a tool angle of 90 degrees with respect to the surface layer. The function is the same for the first tool body TB1 that works at the top of the edge 19 on the side of the locking element 1 with the COMBI 68 tool. Figure 14b shows that the second tool body TB2 of the tool configuration 68 ' on the locking groove side 1 'it can work with a tool angle TA below 90 degrees. In this case, the tool angle TA is equal to the locking angle LA (see also Figures 20a and 20d). The COMBI 68 tool has the same tool angle in this mode. Figures 14c and 14d show that a COMBI tool 68 'with a first and second tool body TB1, TB2 positioned on the same shank can be used to form the horizontal locking surfaces 12, 18 on the locking groove side 1'. The tool angle TA must be adapted to the locking angle LA of the locking surface 12 in the locking groove and the shape of the tongue 10. Locking surfaces up to 80 degrees and even more can be formed if the protruding part of the tongue is limited . Figure 14d shows a locking system without the tongue, and the locking system shown in Figure 2b can also both be formed with a 90 degree tool angle. This locking system should preferably be formed with a rotary tool configuration in relation to the feed direction in order to avoid burring the wear-resistant surface layer by directing the cutting forces inward towards the core.
[00102] Figures 15a to 15c illustrate an exemplary embodiment of a pre-processing step, as shown in Figure 9d, of the wear-resistant surface layer 31 using a rotary tool configuration, according to the invention. Figure 15a shows the coarse cutter 60 positioned at a safe distance ED, for example, 0.5 mm, from the final hinge edge 19 in order to avoid a white line that will be the result if ED is less than the horizontal movement of the floor panel 1 between coarse cutter 60 and fine cutter 62, through which a small bevel is exposed on the white decor paper on the final floor panel. The pre-processing tool 61 can be positioned close to the edge hinge 19, as the tool is placed in conjunction with the fine cutter 62, resulting in virtually no horizontal movement between the pre-processing tool 61 and the thin cutter 62. This , because the two tools are preferably placed in the middle of the machine where it is stable, as opposed to the coarse cutter 60 being placed at the entrance of the profiling line. In addition, the tools are separated with a very small distance and both tools remove a very limited amount of material, creating very limited lateral pressure.
[00103] The pre-processing tool 61 is preferably positioned in such a way that, in relation to the fine cutting tool 62, its final result is a small remaining chamfer 76 in the coating 35, but not so deep that its final result is a chamfer on decoration paper 35, which would create a white line. This chamfer, hereinafter called a micro chamfer, will create a smooth sensation of the edge crest, removing the otherwise common problem with laminate flooring that has rather sharp edges. The sharp edges are a problem for the installer who can cut his hands and also for the consumer with socks damaged at times when walking on the floor.
[00104] The micro chamfer will also maximize the life of the fine cutting tool 62. It should be emphasized, however, that it is possible to position the pre-processing tool 61 a little further out in order to avoid the micro chamfer 76 if desired, for example, in dark decorations where the micro chamfer can show, and still have an acceptable life of the fine cutting tool. By placing the pre-processing tool 61 at approximately 0.1 mm outside the final hinge edge 19, the amount of wear-resistant surface material that the fine cutter has to remove compared to just using a coarse cutter that leaves 0.5 mm of wear-resistant material will be drastically reduced.
[00105] Figures 16a to 16d illustrate the design of mechanical locking systems that can be produced through tool installation solutions, according to the invention. Figure 16a and Figure 16c show a mechanical locking system, according to the prior art, with totally complementary surfaces on the tongue and groove side. However, such systems have proved impossible to produce. The upper contact surface can, in many cases, be very small, causing damage to the upper contact surface when the frames are subjected to forces that press the frames together. This can lead to the creation of gaps that allow dirt and water to penetrate the locking system. This can also cause the top decorative surface to rise and the floor will hang poorly. The upper surface will be, for example, small in very thin frames, for example, 7 mm and below, or for a chamfered frame or if you need to make a large glue pocket 79, industrial openings 79, in Figure 16b and in Figure 16d, in which, for example, a sealing device must be mounted. The solution to this problem is to absorb the forces that press the frames together with a larger contact elsewhere in the locking profiling, for example, a protrusion in the locking strip, which fits with complementary surfaces in a recess on the underside of the tongue . A space between the inner lower contact surface on the protrusion and the complementary surface on the tongue in order to absorb production tolerances to ensure that this contact does not separate the upper contact surface from the frame. However, a solution would be a tool profiling both in the recess and in the upper contact surface on the locking groove side in combination with a double motor installation on the locking element side, thus profiling all critical horizontal surfaces in the same position. This creates a perfect fit and most of the forces directed inward are acquired in the recess, thereby protecting the upper contact surface. In practice, industrial spans 79, in Figure 16b and Figure 16d, were inserted into the mechanical locking systems in order to absorb both vertical and horizontal movement of the floor panel 1, 1 'between the tool installation solutions on the line profiling during production. For example, if gap 79, Figure16d, were removed and traditional tool installation solutions were used, there would be some movement between the tool that cuts 18.19 and 46.46, which would create a space between the upper contact surface 18 , 19 when surface 46 would push surface 56 and a visible gap would emerge. With a space at this point, there would be no pushing.
[00106] With the present invention it is possible to produce both surfaces 19 and 46 or 18 and 56 with one or two tools in the same profiling position. This would eliminate tolerances in the relative positions of the surfaces and no tendency to pull would emerge. Therefore, it is possible to remove gaps 79, in Figure16b and in Figure 16d. This generates additional joint strength for horizontal forces when the frames are pressed together. It can be additionally beneficial to have this feature, of no gap, in, for example, soft core materials such as MDF, or when there is a reduced upper vertical contact surface due to, for example, a deep chamfer or when a large gap is necessary above the tongue.
[00107] Figures 17a to 17e illustrate exemplary modalities of tool installation solutions for a locking system, in which a contact surface 43, 53 constitutes a vertical locking surface, but also a horizontal locking surface for internally directed forces , according to the invention. As one skilled in the art notes in this document, only one contact surface is illustrated, but the principles described are natural and equally important, if there are more than one.
[00108] Figure 17a shows where the tool is removing most of the wear-resistant material.
[00109] Figure 17b shows where the tool is removing most of the core material in order to reduce the amount of material to be removed through the next future tools.
[00110] Figure 17c shows a pre-processing tool installation solution that removes most of the remaining wear-resistant material that the fine cutter should remove in Figure 17d. The preprocessing tool installation solution in Figure 17c is positioned next to the thin cutter in Figure 17d, and positioned in the middle of the profiling line next to the thin cutter.
[00111] Figure 17d shows two alternative tool installation solutions for the groove side. Alternative 1 shows a rotary tool configuration, this installation surface 43 needs to be profiled in the next step shown in Figure 17e. Figure 17e shows a tool installation solution that is separate from the tool installation solution in Figure 17d and horizontal movements of the floor panel will occur, especially since it is in an external position where the floor panel is not always stuck well in the supply chain. This movement will generate a variant vertical fit. If this becomes too loose, it can generate hissing sounds after installation and if it becomes too tight it will make installation more difficult.
[00112] Alternative 2 shows an alternative with a 68 "scraping tool in combination with a 68 rotary tool configuration. With this installation in Figure 17d all vertical and horizontal surfaces are profiled in the same position. This is an important principle that the invention facilitates, which is an extra benefit for locking systems that have surfaces that constitute both the horizontal and the vertical locking surface.As an element skilled in the art would observe, other mechanical locking systems are also applicable, for example, to systems traditional strip locking devices as in Figure 1, where the lower vertical contact surfaces 46, 56 have been removed and an angled locking surface 11, 12 is both a horizontal and a vertical locking surface.
[00113] Figures 18a to 18b are a profiling line that illustrates exemplary modalities of an alternative to the COMBI tool that incorporates a pre-processing step according to the invention. Dual mechanisms 83, 84 are one tool 84 that cuts from the top and the other tool 84 cuts from the bottom. Since these tools are positioned on the same column 80 as the machine and on the same side 88 as column 80, the same effect will be achieved using a COMBI 68 tool. The angle of the tool will then be limited by the surface angle of locking. Tools 83 and 84 can be slightly spaced on column 80, and can operate from the same side of the plate, for example, on the groove side 1 with the angled locking surfaces on the locking element, when tool 83 is greater than tool 84 and this mechanism is angled. This is not possible, as the tool that cuts through the wear-resistant surface layer has been forced to operate in the horizontal plane and thereby blocked other tools from entering the tongue groove. One or both of these tools can be changed to scraping tool settings, and then it is possible to profile all sets of geometries, for example, 90-degree locking surfaces on the locking element. It is crucial for profiling accuracy that the machining point of each tool body needs to close the other. This could also be achieved through the use of several very small rotating tools that can then approach each other due to the small diameters of the tool, that is, technically equivalent with the use of large tools mounted on a column on the same side of the column. If several small tools are used, it is preferable to use one or several large rotary tools to remove most material and use a set of very small motors mounted side by side to remove the final material that creates the final locking surfaces. These can, for example, be spaced no more than 40 mm between each TD tool shank.
[00114] Figures 19a - 19c illustrate the fine cutter tip 93, 94 in an exemplary embodiment of a tool configuration that cuts from below, according to the invention. If the top layer consists of very rigid particles or large particles, the tip of the tool can be so tightened that the corner breaks, especially if, for example, the tip of the tool 94 has a 90-degree angle as in Figure 19b. It is also possible that the tip of the tool is sharper than 90 degrees. If the edge of the tool tip breaks, a rough initial cutting edge will be created, which can engage with the end edge of the floor plate. This, in turn, can create burrs.
[00115] A solution to this problem is to produce the wedge of the tip 93 conformed as in Figure 19a. The initial engagement position will then not be at the end edge portion instead of moving inward gradually as the tool rotates. In the event of a corner break, the rest of the flange will still be sharp and once the flange engagement point moves inward during rotation, the burr will be removed by cutting, generating a portion of the sharp end edge.
[00116] Figures 20a to 20f illustrate an exemplary embodiment of the COMBI 68 tool and how it can vary in position, according to the invention. A COMBI 68 tool works through the rotating cutter around an axis, its stem. Through the angle of the COMBI tool shank at different angles, different angles of the cutting surfaces of the mechanical locking system can be produced. The position of the rod can be varied between being substantially parallel to the top surface layer 31 and being placed in position, so the surface of the rotating disk is equal to the locking angle LA1 -LA2 of the locking surface 11. This means that the teeth cutting edges can be adjusted to profile the locking surfaces with different tool angles. Two different examples are shown in Figures 20a and 20d of vertical locking angles, 90 degrees, and a locking angle of 60 degrees. In Figures 20c and 20f it is shown how corresponding tool angles TA of rotating disk surfaces are adjusted to be able to profile these locking surfaces. The solution on the side of the locking element may vary slightly depending on the geometry of the locking system.
[00117] Figures 21a and 21b are exemplary modalities of equipment for the production of mechanical locking systems on opposite edges of a floor panel comprising a lower chain 70, a belt or upper chain 70a, and various tool configurations for forming the opposite edges according to the invention. The floor panel 1 is moved in a feed direction by the lower chain 70 or the upper chain or belt 70a with its decorative front side in contact with the lower chain. The lower chain is guided vertically and horizontally with a lower guide device 70c. The upper chain or belt is guided in a horizontal direction by an upper guide device 70b and configured so that it presses the floor panel vertically towards the lower chain. Guide devices 70c and 70b are configured so that a horizontal deviation from a linear feed direction between two tool configurations is essentially equal to or less than the upper belt or chain than the corresponding deviation from the lower chain. Figure 21a shows a floor panel 1 which is mainly guided in a linear horizontal direction along the feeding direction with one or more upper belts 70a. Figure 21b shows that the same guide can be made with the upper chains 70a.
[00118] Figure 22a shows an embodiment in which only an upper belt 70a has a horizontal guide device 70b. The other belt 70a 'is a conventional belt. Figure 22b shows that an upper chain 70a or belt that cooperates with a lower chain or belt 70d can be installed between a conventional chain / belt equipment to guide the panel horizontally during machining.
[00119] Several advantages can be achieved with the production equipment in which the horizontal guide is essentially obtained by an upper chain or belt. The rear side of the floor panel, which is in contact with the belt or chain, can be formed with a surface, which can create high friction. The belt or upper chain can also have a high friction surface. Such a surface can even create some fouling on the back without any negative effect on the quality of the floor panel. A very strong connection between the belt or upper chain and the floor panel can be obtained regardless of the surface structure of the decorative side, which is in contact with the lower chain. The equipment also offers the advantages that no additional guide grooves are necessary and that no separate adjustment of the guide parts is necessary if the size of the panel or locking system is changed. Different thicknesses of the floor plate can, for example, be compensated with an upper chain that has a flexible chain plate. The entire chain or belt can also be moved vertically.
[00120] Figures 23a show an exemplary embodiment of a tool configuration 68, according to the invention. Here is an exemplary embodiment of a scraping tool configuration 68 comprising a plurality of burr removal portions 106a-d which are located along the FD feed direction in certain positions with respect to each of a plurality of the other portions burr removal and the edge of a floor panel on which a locking system will be formed. The scraping tool configuration 68 has fixed teeth, each tooth 105a-d is made up of the burr removal portion 106a-d, for example, a cutting surface that will hereinafter be called tip 106, and is configured on a support 107a-d. a typical tooth 105 is attached to an accessory 100 with, for example, a screw 103. Preferably, numerous teeth, i.e., point holders 107, can be attached to the same accessory 100, for example, 2 to 8 or more. An exemplary way of securing teeth 105 is by positioning each tooth on a bar 102 on accessory 100. Each accessory 100 has screw holes 101 to be used to secure the entire accessory 100 to the profiling line. Each tip 106a to d in tip holder 107a to d is arranged in accessory 100 so that each successive tip 106 has a different position horizontally or vertically or both horizontally and vertically. When using the scraping tool configuration, dust and burrs are, for example, easily resolved by simple dust extraction nozzles at each end.
[00121] It is shown how the different tip retainers 105a to d are the same size in accessory 100. Tips 106a to d then follow the tip line. Another exemplary embodiment, according to the invention, is to have the teeth aligned vertically and / or horizontally. The first tooth 105a can, for example, have a size, which is "shorter" than the second "tallest" tooth 105b, etc. In this way, the first tooth 105a would enter the surface of the material to be removed being "short" enough to hit the material to be removed, and the second tooth 105b would now have to remove a next layer of material that is farthest from the tip 106b, and therefore needs to be "taller". In this way, the tips of the accessory 100, when studying from the side, would have an increasing inclination, starting from the first "105th" tooth and ending with the "highest" tooth in the last position 105d.
[00122] Figure 23b illustrates an exemplary embodiment of how production tolerances can be eliminated, according to the invention. Here, the scraping tool configuration 68 is illustrated as an example. The scraping tool configuration then has not only two opposite tool stations in the feed direction, but an upper tool body TB1, as well as a tool body TB2 can eliminate tolerance as they work positioned close to each other, machining cooperative locking surfaces 19, 11; 12, 18 in the same step as the tolerance is decreased. Depending on which locking system it produces, the shape in which the tips are formed and how the teeth are positioned in the accessories depends on whether the material is profiled from above or below.
[00123] It will be understood by those skilled in the art that various modifications and alterations can be made to the present invention without departing from its scope, which is defined by the appended claims.

权利要求:
Claims (7)
[0001]
1. Method for producing mechanical locking systems on a floor panel using a first tool configuration (68) and a second tool configuration (68 '), the floor panel comprising: a surface layer wear-resistant top (31), a core (30) and a mechanical locking system on a first and second edge (1, 1 ') for horizontal locking of the floor panel with other similar panels, with the locking system mechanical comprises: a first pair of locking surfaces on the first edge (1) of a panel and a second pair of locking surfaces on the second opposite edge (1 '), the first pair of locking surfaces comprises a first upper edge (19) ) and a locking element (8), the second pair of locking surfaces comprises a second upper edge (18) and a locking groove (14), characterized by the fact that the method comprises: moving the floor panel in one direction from there (FD) with its first edge (1) relative to the first tool configuration (68) and its second edge (18) relative to the second tool configuration (68 '), the first tool configuration (68) comprises a first and a second tool body (TB1, TB2) positioned on the same side (88) of a second column (80) having two opposite column sides (88, 89), and the second tool configuration (68 ') comprises a first and second tool bodies (TB1 ', TB2') positioned on the same side of a third column (80 ') which has two opposite column sides (88', 89 '), where the first and second tool configurations (68, 68 ') are positioned essentially opposite each other transversely to the feed direction, pre-processing at least a part of the wear-resistant top surface layer (31b) of the floor panel on the first upper edge (19) of such so that properties of the surface layer are changed by removing a pair te of a ridge (76) at the top edge (18, 19) of the wear-resistant top surface layer (31); form through the first (TB1) and the second (TB2) tool body of the first tool configuration (68) at least a part of the first locking surface pair (19, 8) and form through the first tool body (TB1 ' ) and second tool body (TB2 ') of the second tool configuration (68') at least part of at least one of the surfaces of the second pair of locking surfaces (18, 14), in which the pre-processing tool intermediate (67) is positioned on a first column (81) and the first tool configuration (68) comprises a COMBI tool (68) on an adjacent side of the second column (80) so that four rotary tools are positioned on three columns (80, 80 ', 81') and on three column sides.
[0002]
2. Method according to claim 1, characterized in that at least part of the wear-resistant top surface layer (31b) of the floor panel (1 ') is pre-processed on the second upper edge (18) such that the properties of the surface layer are altered, it is carried out before forming at least a part of at least one of the surfaces of the second locking surface pair (18, 14).
[0003]
Method according to claim 1 or 2, characterized in that the first tool configuration (68) is a rotary tool configuration comprising the first tool body (TB1) which has a first tool disc ( 83, 95) and the second tool body (TB2) which has a second tool disc (84, 96), the method further comprising: driving the first and second tool discs with a rotating rod (87), the discs are adjustable with each other.
[0004]
Method according to claim 1 or 2, characterized in that the first tool body (TB1) of the first tool configuration (68) comprises a first tool disc (83, 95) and the second tool body The tool (TB2) of the first tool configuration (68) comprises a second tool disc (96), the method further comprising: driving the first tool disc (83, 95) with a first rotating rod (87) and the second disc tool (84, 96) with a second rotating rod (86), the first (87) and the second (86) rotating rods are mounted on the same side (88) of the second column (80).
[0005]
Method according to claim 3 or 4, characterized in that the first tool configuration (68) has at least the surface of the first tool disc (95) substantially parallel to a 90 degree tool angle ( TA1) of the first tool configuration (68) in relation to the horizontal plane (HP) of the panel or parallel to the locking angle (LA) of the locking surface (11), or substantially parallel to any angle between the 90 tool angle degrees (TA1) of the first tool configuration (68) and the locking angle (LA) of the locking surface (11).
[0006]
Method according to any one of claims 1 to 5, characterized in that the ridge removed (76) from the wear-resistant top surface layer (31) is an edge portion with a thinner thickness than the top surface layer (31).
[0007]
Method according to any one of claims 1 to 6, characterized in that the wear-resistant top surface layer (31) is a mixture of wood fiber or laminate.

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同族专利:

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公开号 | 公开日

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RU2534578C2|2014-11-27|

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EP2459355A4|2017-05-24|

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RU2012102763A|2013-09-10|

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US20160221212A1|2016-08-04|

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CN102470543A|2012-05-23|

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EP2459355A1|2012-06-06|

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JP2013500879A|2013-01-10|

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CA2764965C|2017-10-03|

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US20110023303A1|2011-02-03|

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BR112012001979A2|2019-11-26|

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US20150343577A9|2015-12-03|

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US9314888B2|2016-04-19|

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JP5714582B2|2015-05-07|

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CA2764965A1|2011-02-03|

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US20150107079A1|2015-04-23|

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US10500684B2|2019-12-10|

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EP2459355B1|2020-05-20|

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WO2011014113A1|2011-02-03|

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EP3750676A1|2020-12-16|

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CN102470543B|2016-02-24|

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PL2459355T3|2020-09-21|

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UA107936C2|2015-03-10|

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US8931174B2|2015-01-13|

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法律状态:
2019-12-10| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2020-03-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|

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2020-10-06| B09A| Decision: intention to grant|

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2020-10-20| B09W| Decision of grant: rectification|Free format text: RETIFICACAO DO DEFERIMENTO NOTIFICADO NA RPI 2596 DE 06/10/2020. |

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2020-12-22| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 10 (DEZ) ANOS CONTADOS A PARTIR DE 22/12/2020, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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SE0901054|2009-07-31|

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SE0901054-7|2009-07-31|

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US23449109P| true| 2009-08-17|2009-08-17|

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US61/234,491|2009-08-17|

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PCT/SE2010/050796|WO2011014113A1|2009-07-31|2010-07-08|Methods and arrangements relating to edge machining of building panels|

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