巴西专利BR112012013809B1 METHOD FOR MANUFACTURING FLOOR PANELS

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专利摘要:
Method and Arrangements for Surface Building of Building Panels: The present invention relates to semi-floating floorboards / building panels having mechanical joint systems, a core with curved edge portions of so that the surface layer at the top of the core is located below the panel surface, and where the edges of the floorboard have a bevel, so that the joint system when two floorboards are joined and pressed towards each other, the surface layer (31) and a core portion (30) of the joint edge portion (19) on the second joint edge (4b) overlaps the surface layer (31) which is substantially parallel to the one. horizontal plane of the first joint edge 4a of the other floorboard further, floorboards / building panels are produced by machining the surface structure with a plurality of core grooves (20,20 ') and applying to the surface layer (31) at the upper end of the core (30) to cover at least partly a floor element. a pressure is applied and the surface layer (31) forms around the core grooves (20,20 ').
公开号:BR112012013809B1
申请号:R112012013809-0
申请日:2010-12-17
公开日:2019-07-30
发明作者:Magnus Wallin
申请人:Välinge Innovation AB；
IPC主号:

专利说明:

The present invention relates to a method relating to the manufacture of panels, especially floorboards, as well as to a floorboard produced according to that method. Specifically, the embodiments of the present invention relate to floorboards having mechanical joint systems, a core and a surface layer with curved edge portions located below the panel surface. The modalities of the invention refer to a floorboard with these edge portions and a method for producing that floorboard.
Order Field
The embodiments of the present invention are particularly suitable for use on floors with a top surface layer 15 including wood veneer, laminate, sheets, a paint layer or a layer which comprises a mixture of wood fibers, binders and resistant particles wear and the like. The following description of a known technique, problems of known systems, as well as objects and resources of the invention will therefore be objectified as non-limiting examples in this field of application. However, it should be emphasized that the invention can be used in any building panels, for example, floor panels or wall panels having a top surface layer, which are intended to be joined in different patterns by means of a system. joint theme.
Definition of Some Terms
In the following text, the visible surface of the installed floor panel is called the front side, while the opposite side of the floor panel facing the subfloor is called a rear side. Horizontal plane 30 refers to a plane which is parallel to the front side. Joining directly from the tops of two neighboring joint edges of two floor panels joined together defines a vertical plane perpendicular to the plane
Petition 870190017620, of 02/21/2019, p. 5/12
2/23 horizontal. The outer parts of the floor panel at the edge of the floor panel between the front and the rear side are called the joint edge. As a rule, the joint edge has several joint surfaces, which can be vertical, horizontal, sloped, rounded, beveled, etc. These joint surfaces can exist in different materials, for example, laminate, chipboard, wood, plastic, metal (in particular aluminum) or sealing materials.
With a joint system, it is meant a means of cooperation connection which interconnect the floor panels vertically and / or horizontally. With a mechanical seal system, it means that a lock can occur without glue. However, mechanical joint systems can also be joined, in many cases, with glue.
With side of locking means the side of the floor panel on which part of the horizontal locking means has a locking part whose opening faces the rear side. By means of the locking element side is meant the side of the floor panel on which part of the horizontal locking means has a locking element, which cooperates with the locking pad.
A decorative surface layer means a surface layer, which is mainly intended to give the floor its decorative appearance. Wear-resistant surface layer refers to a high abrasive surface layer, which is mainly adapted to improve the durability of the front side. A decorative wear-resistant surface layer is a layer which is intended to give the floor its decorative appearance, as well as to improve the durability of the front side. A surface layer is applied to the core.
By WFF we mean a mixture of wood fiber binders powder and wear-resistant and similar particles that are compressed under pressure, giving the result of a compact surface layer with a different type of visual effect. The powder can be dispersed.
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Background of the Invention, Known Technique and Problems of the Same
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 the basic construction and function of floorboards with reference to figure 1 in the associated drawings.
Figures 1a to 1d show according to the technique known as a laminate floor is produced. A floor element 3, figures 1a to b, in the form of a large laminated board, is sawn into several individual floor panels 2, figure 1c, which are then further machined to floor boards 1, T, figure 1d. Floor panels are individually machined along their edges for floorboards with mechanical joint systems at the edges. The machining of these edges is carried out on advanced machining machines, where the floor panel is exactly positioned between one or more chains or straps or the like, so that the floor panel can be moved at high speed and with great accuracy, so that passes through various machining engines, which are provided with diamond cutting tools or metal cutting tools and which machinate the floor panel edge and form the joint system.
A floor board 1, 1 ', figure 1d, having a mechanical joint system has active locking surfaces on the wick 10 (the wick side of the T floor board) and the wick plug 9 (the board wedge side) floor 1). A laminate floor and a wood veneer floor are usually composed of a body 30 including a 6 to 12 mm chipboard, a top surface layer of 0.1 to 0.8 mm thick 31 and a bottom balance layer 0.1 to 0.6 mm thick 32. The top surface layer 31 provides appearance and durability to floorboards. The body provides stability and the balance layer keeps the board level when the relative humidity (RH) varies throughout the year. HR can vary between 15% and 90%.
Conventional floorboards with a wooden surface were usually previously joined by means of glued joints of wick and flange. The edges were often formed with bevels, in order to
4/23 if tight tolerances are eliminated.
In addition to these traditional floors, floorboards have been developed in recent years, which do not require the use of glue, but which, instead, are mechanically joined using so-called mechanical joint systems. These systems comprise locking means, which lock the boards horizontally and vertically. Mechanical joint systems can be formed by machining the core 30 of the board 1,
T. Alternatively, the parts of the joint system can be made of a separate material, which is integrated with the floorboard. The floorboards are joined, that is, interconnected or locked together in a floating manner, by various combinations of inclination methods, pressure connection fitting, insertion along the joint edge and by folding using joint systems comprising wicks separate movable shells usually inserted at the factory in a slot at the short edges.
These floors can be formed with firm tolerances. Therefore, bevels are used mainly for obtaining decorative properties. A laminate floor panel with a thin surface layer can be formed with beveled edges and then look like a solid plank of wood.
The advantage of a floating floor, which is not connected to a subfloor, for example, with nails or glue, is that a change in shape due to different degrees of RH relative humidity can occur hidden under the base moldings and planks. floors can be joined, although they expand and retract, with no visible joint spaces. An installation can be deposited quickly and easily, especially by using mechanical seal systems. The drawback is that the continuous floor surface must be limited, as a rule, even in cases where the floor comprises relatively dimensionally stable floorboards, such as laminate flooring with a chipboard core or wooden floors composed of several layers with different fiber directions. The reason for this is that these floors as a rule retract and expand as HR varies.
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One solution for large floor surfaces is to divide the large surface into smaller surfaces with expansion strips. Without this division, there is a risk that the floor, when retracting, will change shape, so that it is no longer covered by the base moldings. Also, the load on the joint system will be large, since large loads must be transferred when a large continuous surface is moving. The load will be particularly large when crossing different rooms. Examples of expansion strips are joint profiles that are generally of aluminum or plastic section fixed to the floor surface between two separate floor units. They collect dirt, provide an unwanted appearance and are quite expensive. Due to these limitations on maximum floor surfaces, laminate floors have only reached a small market share in commercial applications, such as hotels, airports and large shopping areas. More unstable floors, such as wooden floors, can exhibit major changes in shape. The factors that above all affect the change in the shape of homogeneous wooden floors are the direction of fiber and the type of wood. A homogeneous oak floor is very stable along the fiber direction, that is, in the longitudinal direction of the floorboard.
The advantage of gluing / nailing the subfloor is that large continuous floor surfaces can be provided, without expansion joint profiles, and the floor can withstand heavy loads. This method of installation involving the affixing to the subfloor, however, has a number of considerable drawbacks. The main drawbacks are costly installation and that, as the floorboards retract, a visible joint space appears between the boards.
In view of the aforementioned documents, there is still a need to improve a floating floor without the above inconveniences, in particular a floating floor which a) can have a large continuous surface without expansion joint profiles, b) can have a space of non-visible joint, and c) can have a bevel with the same visual effects as for a more expensive wood-based floorboard. There is still a need
6/23 improvement of a method for the production of a floating floor like this, without the above drawbacks in particular a manufacturing method which can be less complex, thereby speeding up manufacturing and lowering the cost.
Summary of the Invention and Objectives
A first objective of an exemplary embodiment of the invention is to allow improved joint systems, so that it is possible for floorboards to be installed as semi-floating floors on large continuous surfaces, although large dimensional changes may occur as the relative humidity changes.
A second objective of an exemplary embodiment of the invention is to provide joint systems, which allow considerable movement between the floorboards, while preventing moisture from entering, or at least decreasing the moisture that penetrates into the joint spaces, and no large, deep joint spaces that collect dirt, and or where open joint spaces can be excluded.
A third objective of an exemplary embodiment of the invention is to provide joint systems, which allow considerable movement between floorboards with bevels at the edges which are strong.
A fourth objective of an exemplary embodiment of the invention is to allow an improved manufacture of wood veneer floorboards with a bevel, which can also be semi-floating.
A fifth objective of an example embodiment of the invention is to allow the possibility of applying a bevel to a floor board with a production gear shift unit that is less complex and thus requires less complex machines and machines at a low cost. , and allow high-speed production.
According to a first aspect, the embodiments of the invention include floorboards provided with an upper decorative surface layer. The floorboards comprise a mechanical joint system on two opposite edges for locking together joint edges of two adjacent floorboards. The decorative surface layer
7/23 on a first joint edge and the decorative surface layer on a second joint edge overlap each other in the mechanical joint system in an overlapping part, the overlapping part is preferably located under the horizontal main surface of the layer With a decorative surface, a first joint surface of the first joint edge faces a second joint surface on the second joint edge and the first and second joint surfaces are essentially parallel and essentially horizontal.
According to a first aspect, a preferred embodiment of the invention is that the first and second joint surfaces are in contact. Another preferred example embodiment is that the first and second joint surfaces extend in a plane which is around 0 to 10 ° with the horizontal plane.
According to a second aspect, the modalities of the invention include a method for the manufacture of a floor panel, the method comprising the steps of:
• machining a plurality of core grooves on the upper horizontal surface of a floor element;
• application of a top surface layer to the core of the floor element;
• applying pressure to at least parts of the surface layer, so that the surface layer follows the surface of the floor element and at least partially the surface of at least one of the core grooves;
• cutting the floor element into at least two floor panels in at least one of the core grooves of the floor element, so that the floor panels comprise at least part of the core groove on one edge of the floor panel.
According to the second aspect, a preferred embodiment of the invention is that the method further comprises the step of forming a mechanical joint system at the edge of the floor panel.
An advantage of some exemplary embodiments of the invention
8/23 tion is with the special design of the mechanical joint system allowing a semi-floating installation, and regardless of retraction or expansion of the floorboard, due to changes in temperature or humidity, any visible openings between the floor panels are eliminated.
An advantage of some example modalities of the invention is that with the special design of the mechanical joint system allowing a semi-floating installation, the possibilities of sealing the moisture joint system are provided, without the possibility of moisture penetrating or with the extra help of a vapor barrier disposed under the overlapping surface or over the surface being overlapped.
An advantage of some exemplary embodiments of the invention is that the visible joint opening will have the same type of wood and fiber direction as the top surface layer and the appearance will be identical to that of a homogeneous wooden floor.
An advantage of some exemplary embodiments of the invention is that a support is provided for the overlapping joint edge by facing the top surface layer of the locking joint edge to be horizontal.
An additional advantage of some exemplary embodiments of the invention is that it allows the possibility of applying a bevel to a floorboard with a production method that is less complex and, therefore, requires less complex machines and machines at a low cost, and high-speed production.
An additional advantage of some exemplary embodiments of the invention is that a veneer floorboard with a bevel can be produced at a low production cost and still has the same visual effects as a more expensive floorboard. , that is, a floorboard with a thick top surface layer of a solid wood floorboard.
An additional advantage of some exemplary embodiments of the invention is that a floorboard with a wood fiber mixing surface with a bevel can be produced at low production cost.
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Yet another advantage of some exemplary embodiments of the invention is the reduced tolerances, albeit with high-speed production of floorboards with a bevel.
The method described above for the manufacture of a floor element comprising a surface according to beams or even local cavities formed in the core can also be used to form decorative depressions on the surface of a floorboard between two edges. This allows thin surfaces with similar deep structures, for example, grout lines, hand sanded wood, rough stone and slate-shaped structures, to be formed in a cost-efficient manner. These structures are difficult to form with known production methods, where a compression of the surface layer and / or the core is used to obtain the example local depressions on the surface.
Other objectives, advantages and new features of the invention will become apparent from the following detailed description of the invention, when considered in conjunction with the associated drawings and claims.
Brief Description of Drawings
Figures 1a to 1d are steps on how a floorboard is produced in the known technique.
Figures 2a to 2b are the first two examples of a special design of a mechanical joint system that allows a semi-floating installation, according to the invention.
Figures 3a to 3d are a second example modality, with two different dimensions of a special design of a mechanical joint system, in two different positions, which allows a semi-floating installation, according to the invention.
Figure 4 is a special design of a mechanical joint system that allows for a semi-floating installation.
Figures 5a to 5b are a third example of a special design of a mechanical joint system, in two positions
10/23 different, which allows a semi-floating installation, according to the invention.
Figure 6 is a fourth example of a special design of a mechanical joint system, which allows a semi-floating installation, according to the invention.
Figures 7a to 7c are detailed views of example embodiments according to the invention.
Figures 8 to 15 are examples of different stages of manufacturing a special design of a mechanical joint system that allows a semi-floating installation according to the invention.
Figures 16a to 16f are an example embodiment of a summary of the manufacturing steps in figures 8 to 15, according to the invention.
Detailed Description of Modalities
Figures 2 to 16 and the related description below are used to explain certain principles of the invention and to show examples of modalities that can be used in the invention. The illustrated modalities are just examples. It should be emphasized that all types of floorboard mechanical joint systems allowing vertical folding and / or vertical locking can be used and applicable to part of this description to form a part of the present invention.
The present invention of a special design of a mechanical joint system that allows for a semi-floating installation and a method for the production of these building panels are particularly suitable for, but are not limited to use in:
• Floorboards where the top surface layer includes a wood veneer, a laminate, a paint layer or a solid layer comprising a mixture of wood fiber, binders and wear-resistant particles or the like.
• Floor boards with a bevel having the same material as the top surface layer with the benefit of a bevel extending to the floor board wick.
11/23 • Floorboards with a bevel in combination with a clearance, which results in a semi-floating feature, can occur, and the movement of the profile will not affect the visual impression with spaces.
• Wall panels in damp rooms where no space is allowed.
• Being less precise, the present invention is suitable for any building panels having joint systems with a bevel having the same material as the top surface layer.
Figures 2a to 2b illustrate the first example modalities of the special design of a mechanical joint system for the mechanical joining of floorboards 1, T, which allow a semi-floating installation, without a visible joint space and without the use of grade wood. high, according to the invention. The floorboard comprises a surface layer 31 applied on top of a core 30. The joined floorboards have a horizontal plane (HP), which is parallel to the horizontal main floor surface and comprises external parts of the surface layer, and a vertical plane (VP), which is perpendicular to the horizontal plane. The joint system has mechanical cooperation locking means for the vertical joint parallel to the vertical plane and for horizontal joint parallel to the horizontal plane of a first and a second joint edge 4a, 4b. The vertical locking means comprises a lock 10, which cooperates with a locking lock 9. The horizontal locking means comprises a strip 6 with a locking element 8, which cooperates with a locking lock 14. The floorboards 1.1 'have, in an area TT of the first 4a and the second 4b joint edge a first 18 and a second 19 joint edge portion, which are defined by the area between the upper parts of the wick 9 and the HP horizontal plane.
Figures 2a to 2b show edge parts which are sharpened in Figure 2a or rounded in Figure 2b, and comprise an upper horizontal foreground H1 extending through a surface layer 31, an intermediate horizontal second plane H2 extending through a part of the panel core 30 and a lower horizontal plane H3
12/23 extending through a portion of the surface layer 31.
Figure 2a illustrates the surface layer H1a in the top horizontal foreground H1 parallel to the main floor surface HP, the top layer H3a in the bottom horizontal plane H3 located under the main floor surface HP, and part of the core H2a in the second horizontal plane H2 between the first and second horizontal planes Η1, H3. When floorboards 1,1 'are joined and pressed towards each other, the surface layer H1a and the core H2a of the upper joint edge portion 19 on the second joint edge 4b overlaps the surface layer H3a of the first joint edge 4a. The surface layers H1a and H3a can have substantially the same thickness. Core H2a is preferably thicker than surface layers H1a and H3a.
The locking flange 14 and the locking element 8 can be formed with a small gap or space, as shown in figure 2a, and this allows the floorboards to move horizontally, so that expansion and retraction are partially compensated or completely and that a semi-floating floor is obtained. The first joint edge 4a and the decorative surface layer 31 of the second joint edge 4b overlap each other in the mechanical joint system in an overlapping part 31a, and allow this movement to be achieved without any visible joint spaces. The overlapping part 31a is located under the horizontal main surface HP of the decorative surface layer 31. In the overlapping part 31a, the first joint surface 4c of the first joint edge 4a faces a second joint surface 4d of the second joint edge 4b and the first and second joint surfaces are essentially parallel and essentially horizontal. The first and second joint surfaces 4c, 4d are in contact, and the first and second joint surfaces extend in a plane which has around 0 to 10 ° with the horizontal plane and they can be formed with an adjustment precise, and this will prevent moisture from entering the joint.
The joint system in figure 2b shows that the joint can be formed with a firm fit or even with vertical and / or horizontal pre-tension
13/23 horizontally, and this can be used to improve resistance to moisture. The upper part of the overlapping part 31a can be machined and adjusted slightly to eliminate production tolerances. This means that the overlapping part 31a on the wick 10 can be made thinner than the surface layer 31 covering the upper part of the floorboard T.
The TT portion can be divided into an upper joint edge portion and a lower joint edge portion or not divided into portions. Here, the first joint edge 4a has a joint edge portion 18 and in a corresponding area of the second edge 4b a joint edge portion 19. When floorboards 1, T are pressed together, a portion of the layer surface 31 of joint edge portion 18 is located on the horizontal plane HP, if the horizontal plane HP is on the same level as the main floor surface. In the joint system, when the floorboards 1,1 'are joined and pressed towards each other, a portion of the surface layer 31 and a portion of the core 30 of the joint edge portion 19 of the second joint edge 4b overlaps with a portion of the surface layer 31 of the first joint edge 4a. An advantage of the first joint edge 4a having a portion of the horizontal surface layer H3a in the lower horizontal plane H3 superimposed by the surface layer H1a and the core portion H2a of the second joint edge 4b of the joint edge portion 19 is that a support is obtained during movement between the two floor panels and without visible joint spaces.
The surface layer 31 of the first joint edge 4a and the surface layer 31 of the second joint edge 4b overlap each other in the mechanical joint system in an overlapping part 31a, said overlapping part 31a is located under the horizontal plane HP of the decorative surface layer 31. A first joint surface 4c of the first joint edge 4a faces a second joint surface 4d of the second joint edge 4b, and the first and second joint surfaces are essentially parallel and essentially horizontal . The first and second joint surfaces 4c, 4d of the floorboards 1,1 'can then be in contact. The first and second joint surfaces of the
14/23 floor 1, Γ extend in a plane which is around 0 to 10 ° with the horizontal plane.
Figures 3a to 3d illustrate a second example modality with dimensions different from the special design of a mechanical joint system that allows a semi-floating installation, according to the invention. The TT area of the first joint edge 4a has a lower joint edge portion 17 positioned between the wick 10 and the surface layer 31, and an upper joint edge portion 18 'which is closest to the main floor surface HP than the lower joint edge portion 17, and the second joint edge 4b has a lower joint edge portion 16 positioned between the wick 10 and the surface layer 31, and an upper joint edge portion 19 'which is closer to the HP main floor surface than the lower joint edge portion 16. In the joint system, when the floorboards 1.1 'are joined and pressed towards each other, the joint edge portion upper part 19 'and a portion of the core 30 on the second joint edge 4b overlap with the surface layer 31 of the lower joint edge portion 17 of the first joint edge 4a.
Figure 4 illustrates a special design of a mechanical joint system that allows a semi-floating installation. The joint edge portion 18 is sloping away from the HP main floor surface. The joint edge portion 19 with the surface layer 31 and a part of the core is overlapping the angled surface layer 31 and the core 30 of the joint edge portion 18.
Figures 5a to 5b illustrate a third example of the special design of a mechanical joint system that allows a semi-floating installation, according to the invention. The second joint edge portion TT 4b is divided into portions, while the first joint edge 4a is not. The second joint edge 4b has a lower joint edge portion 16 positioned between the wick 10 and the surface layer 31, and the upper joint edge portion 19 'is closer to the main floor surface HP than the lower one. 16. When floorboards 1.1 'are joined and pressed towards each other, the joint edge portion 18 on the
15/23 second joint edge 4b overlaps the lower joint edge portion 16 on the second joint edge 4b, and the upper joint edge portion 19 'and a portion of the core 30 on the second joint edge 4b overlap the surface layer 31 of the joint edge portion 18.
Figures 3b, 3d and 5b illustrate the boards pressed together in their internal position, with the joint edge portions 16, 17 or 16, 18 in contact with each other, and figures 3a, 3c and 5a illustrate the planks apart to its external position, with the joint edge portions 18 ', 19' or 18, 19 'spaced from each other.
In the above example embodiments, the overlapping joint edge portion 19 'is made on the joint side, that is, on the joint edge having a joint 9, on the second joint edge 4b. The overlapping joint edge portion 18, 18 'can also be made on the wick side, i.e., on the joint edge having a wick 10, or on the first joint edge 4a, as shown in figure 6.
A piece of flexible material can be applied by reducing the movements between two floor panels mechanically joined in the vertical plane VP on the side of the wick or flange or on both sides. Examples of flexible materials are plastic, rubber and silicone or a similar material.
A piece of moisture removal material can be applied in the vertical VP plane on the wick or pad side or on both sides. This material prevents moisture from passing between two floor panels.
In the pressed position together, the joint system has a gap JO, for example, 0.2 mm. If the overlap in this position pressed together is 0.2 mm, the boards may separate, when they are separated, from each other 0.2 mm, without a visible joint space being seen from the surface. The modalities will not have a visible joint space, because the joint space will be covered by the second overlapping joint edge portion 19, 19 'in figures 3 to 5 and by the overlapping of the first joint edge portion 18 in figure 6. It is an advantage that the locking element 6 and the locking pad 12 are such
16/23 that the possible separation, that is, the gap, is slightly less than the amount of overlap. Preferably, a small overlap, for example, 0.05 mm, should exist in the joint, even when the floorboards are spaced apart and a pulling force is applied to the joint. This overlap will prevent moisture from entering the joint. The joint edges will be strong, since the overlapping edge portion 19, 19 'on the second joint edge 4b will be supported by the horizontal surface of the edge portion 18 of the first joint edge 4a of the adjacent floorboard in figures 2 , 4 and 5, or even stronger in figures 3a to 3d, since the lower edge portion 17 will support the upper edge portion 19 '. The decorative panel can be made very shallow, and all the dirt collecting on the panel can be easily removed by a vacuum cleaner in relation to normal cleaning. No dirt or moisture can penetrate the joint system and down to the fuse 10. This technique involving overlapping joint edge portions, obviously, can be on one side only, or combined on both long sides or on both sides short, or combined on all sides on the floorboard including the long short sides. For example, the visible and open joint space can be 0.1 mm, the compression 0.1 mm and the overlap 0.1 mm. The possibility of movement of the floorboards will then be 0.3 mm, all together, and this considerable movement can be combined with a small visible open joint space and a limited horizontal extent of the overlap joint edge portion 19, 19 'which does not have to weaken the joint edge. This is due to the fact that the overlap joint edge portion 19, 19 'is very small and also made in the strongest part of the floorboard, which comprises the surface of the laminate, and wood fibers impregnated with melamine. Such a joint system, which can thus provide a considerable possibility of movement without visible joint spaces, can be used in all the applications described above. Furthermore, the joint system is especially suitable for use on wide floorboards, on short sides, when the floorboards are installed in parallel and similar rows, that is, in all applications
17/23 that require great mobility in the joint system to counterbalance the dimensional change of the floor. It can also be used on the short sides of the floorboards, which constitute a frame or crimp around the floor installed in a zigzag pattern. In an example embodiment, the vertical extent of the overlap joint edge portion, that is, the depth GD of the joint opening, is less than 0.1 times the floor thickness T. The overlap joint edge is still can be reinforced at the edge if desired. For example, by pre-processing the surface layer, so that the surface layer is reinforced at the edges or by an extra layer of reinforced material at the core of the beams.
Figures 7a to 7c illustrate in detail some parts of the example modalities of figures 2 to 6, according to the invention. In figure 7b, the surface layer 31 and a part of the core 30 on the second joint edge 4b of edge 1 are overlapping the surface layer on the edge of the adjacent floorboard T, or, as in figure 7a, the floorboard floor and a portion of the core 30 on the floorboard edge T of the first joint edge 4a are overlapping the surface layer on the adjacent floorboard edge 1. The edge portion comprises a surface layer H1a in the horizontal foreground upper horizontal H1 with the main floor surface, a part of a panel core H2a and a surface layer H3a in the lower horizontal third plane H3 lower than the main floor surface. A fifth horizontal plane H5 is parallel to the wick 10 at the first joint edge 4a in figures 7b to 7c, and a sixth horizontal plane H6 is parallel to strip 6 of the locking element 8 at the second joint edge 4b in figure 7a.
Figure 7a illustrates the surface layer H1a in the upper horizontal foreground H1 parallel to the main floor surface HP, the middle of air volume control H3a in the lower horizontal horizontal plane H3 located under the main floor surface HP, and a portion of the core H2a in the second intermediate horizontal plane H2 between the first and third horizontal planes. When floorboards 1, T are joined and pressed together
18/23 towards each other, the surface layer H1a and the core part H2a of the upper joint edge portion 18 'on the first joint edge 4a overlap with the surface layer H3a adjacent to the joint edge 19' on the second joint edge 4b.
The invention further provides the exemplary modalities of a production method for forming deep core beams 20 ', 20 on a panel with a thin surface layer. The advantage is that these deep core bonds can be formed very accurately, without any substantial compression of the core, and in a production method with reduced production time and using little energy in the same way, thereby reducing the cost of production.
Figures 8 to 16 show parts of a production line illustrating the example modalities of how to produce beveled building panels, reducing the production cost, time and energy, according to the invention. The process of producing floorboards / building panels comprising pre-forming the core material of the entire floor element 3, without separating the floor panels 2 from each other, applying a top surface layer, for example , of wood veneer, laminate, paint layer or a solid layer comprising a mixture of wood fiber, binders and wear resistant particles or the like, forming the top surface layer 31 around the preformed core beams 20 ', 20 in the core material 30. The floor element 3 is then separated into the floor panels 2. The method for making the floor panels 2 is described here, now, in the following method steps:
• machining a plurality of core grooves (20 ', 20) on the upper horizontal surface of a floor element (3);
• applying a top surface layer (31) to the core (30) of the floor element (3);
• applying pressure at least in parts of the surface layer (31), so that the surface layer (31) follows the surface of the floor element and at least partially the surface of at least me19 / 23 in one of the grooves core (20 ', 20);
• cutting the floor element (3) into at least two floor panels (2) in at least one of the core grooves of the floor element (3), so that the floor panels comprise at least part of the floor groove core on one edge of the floor panel.
Figure 8a illustrates an example embodiment of a production method for preforming a core 30 with core pads 20, 20 ', 20, which are intended to be covered with a surface layer 31, and formed as depressions surface on a floorboard preferably as bevelled edges, according to the invention. Figure 8a shows the machining by rotary cutting tools. Preferably, saw blades 51 on an axis 50 can be used for cutting core beams 20, 20 ', 20, which can be positioned so that they cover a portion of the edge above the fuses 10 and beams 9 in the joint system that will be formed at the edges of the floorboard, as shown in figure 8b. Various other methods can be used for forming the beams by machining. Laser cutting or scraping, lamination or corrosion are other alternatives for the formation of bowl 40 by machining core beams 20, 20 ', 20. An advantage of machining in this way is that the core surface is stable. As a person skilled in the art appreciates, depressions can have a core 20, 20 ', 20 core surface structure that follows the sides of a floor panel on the two long sides, or follows only one long side, or can still follow the short sides or just the short sides can be followed by the core beams, depending on where the joint systems are to be positioned on the semi-floating floor. Core glands can also be formed only for visual effects in the center of the floorboard, for example, not shown.
Figure 9a illustrates the example modality of adding adhesives 53 with a machine 52 to the core 30, on the pre-formed surface of the core, according to the invention. This makes it easier for the top surface layer 31 to be affixed to the core after pressing. According to a person
20/23 sounds versed in the appraisal technique, any type of adhesive can be used, for example, polyvinyl acetate (PVA), an emulsion of aliphatic resin or other synthetic resins, including resorcinol, urea-formaldehyde, phenol formaldehyde resin, etc. ., just to mention a few.
Figure 9b illustrates the example humidification mode 53 with a machine 52 of the top surface layer 3Γ, 31, before pressing, according to the invention. This facilitates, for example, the flexing of a wood fiber based on the top surface layer, such as paper or veneer around the preformed portion 20 of the core 30, that is, the surfaces which are lower than the main floor surface. As a person skilled in the art appreciates, any form of humidification 53 can be done, for example, by spraying, using steam, painting with liquid or lubricant, and any type of humidifier 53 can be used, such as, for example, water , oil or wax, etc., just to mention a few. In addition, the top surface layer 3Γ, 31 can be heated until the top layer softens, which will then be more easily formed during pressing.
The method can be used for the formation of core and main floor surfaces in the same production step. A paper impregnated, for example, with a thermosetting resin, can be applied over the core pad and, under heat and pressure, thereby forming around the depression and curing the top surface layer.
The method is particularly suitable for the formation, for example, of deep depressions in the floorboards comprising a solid surface of wood fibers, binders and wear-resistant particles.
The method does not exclude that the core and / or parts of the core seam are partially compressed during the application of the surface layer on the core seam.
Figure 10a illustrates the example embodiment in which each floor panel 2 ', 2 is more or less covered by a separate sheet 3Γ,
21/23 of a top surface layer according to the invention. Figure 10b illustrates the embodiment when the top surface layer 3T is covering an entire floor element 3, which can be slightly stretched when pressed down between the bevels 20, 20 ', 20, according to the invention. Figure 10c is a detailed view of Figure 10b, where it can be seen that a thin top surface layer 31 'is applied to the core 30, so that it covers the core pads. Figure 11 illustrates the exemplary embodiment according to the invention, where a top surface layer 31 p is applied as a powder, comprising fibers and binders, in the shape defined following the outline of the preformed core. An example of a powder is WFF defined in WO 2009/065769. The powder applied to the core can be a different color than that of the main floor surface. This could be used to form deep grout lines with a different color or structure than the main floor surface. The powder can be dispersed to cover at least one core core, and the powder can still be lubricated, if necessary.
Figures 12a to 12c illustrate the example of pressing in a different top surface layer 3Γ, 31, 3T, 31 p in a first stage, according to the invention, using, for example, a pressure plate fixed 54, with a defined shape following the outline of the preformed core beams (20, 20 ', 20). The pressure plate 54 shown, as a person skilled in the art appreciates, can have any shape that suits the surface layer to be pressed. The top surface layer can be glued to the core or laminated under heat and pressure as a 3T, 31, 3T impregnated paper or applied as a powder 31 comprising fibers and binders. Figure 12d illustrates the second step in which the pressing plate 54 is in a pressure position. Figure 12e shows the result after pressing. Scraping, cutting or corrosion can form the surface structure of the upper surface of the core, and the sheets 31, 3T, 31, 3Γ of the opposite surface layer or powder mixture then proceed with the pressing. The top surface layer can also be pre-processed before being pressed, for example, with
22/23 a scraping or cutting of laminated sheets 31, 3Γ, 3Γ with patterns. In addition, the upper surface layer may comprise a moisture-repellent material.
Figures 13a to 13b illustrate the modality of a soft pressure device 54, 55 working, for example, with a soft web between the flat formed press 54 and the top surface layer 3T, 31, according to the invention. When pressing the flat press 54, the blanket 55 swells outward to where the open spaces are, due to the preformed core beams (20 ', 20) on the surface of the core 30. The bulky part of the blanket 55 presses the top surface layer 3T, 31, even on the lower surface, helping the top surface layer 31 to follow the contour of the core surface 30, and affixing the top surface layer 31. According to a knowledgeable person in the appraisal technique, the pressing plate can have any shape that suits the surface layer to be pressed together with the mat 55.
Figures 14a to 14b illustrate the modality of a press plate 54 having only projected portions 56 which correspond to the core pads (20, 20) and a roller 57 rolling over the top surface layer 31, according to the invention. . Both the projected portions and the roller 57 are following the contour surface, affixing the top surface layer to the surface 30, particularly affixing the top surface layer to the preformed bevels 20.
Figure 15 illustrates the modality of the step after the pressing step, which is separating the floor element 3 in floor panels 2 with a cutter 58.
Figures 16a to 16f illustrate the modality of the different steps through which the floor element 3 passes during the production line, according to the invention. Figure 16a illustrates the floor element 3. Figure 16b illustrates the floor element 3 after pre-forming the core 30. The top surface layer sheets 31 'are applied in figure 16c. After pressing, the sheets are displayed in figure 16d. The floor element 3 is separated into floor panels 2 and the joint systems are machined in figure 16e.
23/23
Figure 16f illustrates the surface layers not overlapping each other, an example design of a mechanical joint system according to the known technique, not allowing a semi-floating, where the manufacturing method according to the invention is suitable for the same way.
The example modalities of manufacturing methods, in figures 8 to 16, can be used in the production of example modalities of the building panel, in figures 2 to 7, with a special design of a mechanical joint system that allows a semi-floating installation .
It will be understood by those skilled in the art that various modifications and changes can be made to the present invention, without deviating from its scope, which is defined by the appended claims.

权利要求:
Claims (14)
[1]
1. Method for the manufacture of floor panels (2), characterized by the fact that the method comprises the steps of:
• machining a plurality of core grooves (20 ', 20' ') on the upper horizontal surface of a floor element (3);
• applying a top surface layer (31) to the core (30) of the floor element (3);
• machining the plurality of core grooves (20 ', 20' ') by mechanical cutting, or milling, or scraping before applying the surface layer (31);
• applying pressure to at least parts of the surface layer (31), so that the surface layer (31) follows the surface of the floor element and at least partially the surface of at least one of the core grooves (20 ', 20' '); and • cutting the floor element (3) into at least two floor panels (2) in at least one of the core grooves of the floor element (3), so that the floor panels comprise at least part of the groove core on one edge of the floor panel.
[2]
2. Method, according to claim 1, characterized by the fact that the method still comprises the step of forming a mechanical joint system at the edge of the floor panel.
[3]
Method according to any one of the preceding claims, characterized in that the top surface layer (31) is applied by applying a mixture of fiber powder and binders and wear-resistant particles, and applying pressure at least in parts of the mixture providing the result of a compact top surface layer with a different type of visual effect.
[4]
Method according to claim 3, characterized in that the powder mixture is dispersed to cover at least one core groove (20 ', 20' ').
[5]
5. Method according to any of the preceding claims, characterized by the fact that at least one of the
Petition 870190017620, of 02/21/2019, p. 6/12
2/3 cutting core (20 ', 20' ') comprises a bevel for at least one side of each floor panel (2).
[6]
6. Method according to any of the preceding claims, characterized by the fact that at least three cutting core grooves (20 ', 20' ') are formed and the three core grooves (20', 20 '') comprise the structure of at least two floor panels (2) with bevels on two sides of each floor panel (2).
[7]
Method according to any one of the preceding claims, characterized in that the pressure is applied by a vertical pressing or by rolling a roller or a combination of vertical pressing and rolling a roller.
[8]
Method according to any one of the preceding claims, characterized in that the pressure is applied by a pressure plate comprised of a material that will follow the contour of the plurality of core grooves (20 ', 20' ').
[9]
Method according to any one of the preceding claims, characterized in that the pressure is applied by a pressure plate (54) comprising at least one fixed pressure plate with the shape adapted to form the plurality of grooves of core (20 ', 20' ') or with a flat shape.
[10]
Method according to any one of the preceding claims, characterized in that a soft flexible mat (55) is positioned on top of the surface layer (31) under the pressure plate.
[11]
Method according to any one of the preceding claims, characterized in that the top surface layer (31) is glued to the core or laminated under heat and pressure.
[12]
12. Method according to any one of the preceding claims, characterized in that it comprises humidification or lubrication or oil lacquering or lubrication or the placement of adhesives in the core (30) before pressing.
[13]
13. Method, according to any of the preceding claims, characterized by the fact that it comprises the application of
Petition 870190017620, of 02/21/2019, p. 7/12
3/3 a piece of moisture removal material in the vertical plane (PV) on the wick or pad side.
[14]
Method according to any one of the preceding claims, characterized in that the top 5 surface layer (31) comprises a laminate or a wood veneer.

类似技术:

公开号 | 公开日 | 专利标题

BR112012013809B1|2019-07-30|METHOD FOR MANUFACTURING FLOOR PANELS

US9970199B2|2018-05-15|Floorboard, system and method for forming a flooring, and a flooring formed thereof

JP4642781B2|2011-03-02|Cover and locking system for floor and apparatus for producing floorboard, for example

US7137229B2|2006-11-21|Floorboards with decorative grooves

EP2287418B2|2021-10-13|Floor panels

KR101227004B1|2013-01-28|Floorboard, system and method for forming a flooring, and a flooring formed thereof

BR112014003962B1|2021-04-13|FLOOR PANELS PROVIDED WITH A LOCKING SYSTEM

JP2004537663A5|2005-11-17|

同族专利:

公开号 | 公开日

US20110146188A1|2011-06-23|

JP5763096B2|2015-08-12|

CN102652201B|2014-11-12|

BR112012013809A2|2016-05-03|

US8591691B2|2013-11-26|

EP2513386A4|2017-11-15|

US20140069044A1|2014-03-13|

CA2782869C|2018-02-13|

CN102652201A|2012-08-29|

EP2513386A1|2012-10-24|

EP3623543A1|2020-03-18|

CA2782869A1|2011-06-23|

US20150361676A1|2015-12-17|

JP2013514473A|2013-04-25|

UA107205C2|2014-12-10|

KR101778006B1|2017-09-13|

RU2012127367A|2014-01-27|

US9169654B2|2015-10-27|

KR20120101491A|2012-09-13|

EP2513386B1|2019-11-06|

US9447587B2|2016-09-20|

RU2540743C2|2015-02-10|

WO2011075074A1|2011-06-23|

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法律状态:
2019-01-02| B06T| Formal requirements before examination|

2019-01-08| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

2019-06-04| B09A| Decision: intention to grant|

2019-07-30| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 17/12/2010, OBSERVADAS AS CONDICOES LEGAIS. (CO) 20 (VINTE) ANOS CONTADOS A PARTIR DE 17/12/2010, OBSERVADAS AS CONDICOES LEGAIS |

优先权:

申请号 | 申请日 | 专利标题

SE0950980-3|2009-12-17|

SE0950980|2009-12-17|

PCT/SE2010/051418|WO2011075074A1|2009-12-17|2010-12-17|Method and arrangements relating to surface forming of building panels|

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