• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method is provided for producing a beveled edge having a depth d on at least one edge of a top surface of a plate-shaped article. The method includes the steps of: (a) heating the article; (b) engaging with pushers to form the beveled edge by displacing material from the topsheet while displacing an amount of material beyond the original boundary of the article; and (c) removing the displaced amount of material.
    公开号:BE1019226A5
    申请号:E2011/0060
    申请日:2011-02-02
    公开日:2012-04-03
    发明作者:Vlassenrode Kristof Van；Filip Gilbert Lucien Bossuyt
    申请人:Ivc N V；
    IPC主号:
    专利说明:

    Method for manufacturing a beveled edge and plate-shaped object provided with such a beveled edge
    The invention relates in the first place to a method for manufacturing a beveled edge according to the preamble of claim 1, as is known from US-A-5,240,751. With this known method, the material to be moved in the lateral direction is first moved horizontally beyond the original limits thereof.
    An important field of application of the present method relates to the manufacture of panels for floors, walls and ceilings. The beveled edge will provide the panel with a decorative appearance. A known method for manufacturing such a chamfered edge comprises the use of mechanical processing tools for removing material chips at the chamfered edge.
    It is an object of the present invention to provide an alternative method of the above-mentioned type.
    Thus, in accordance with the present invention, a method is provided for manufacturing a chamfered edge with a depth d on at least one edge of an upper surface of a plate-shaped article, wherein at least one top layer of said plate-shaped article is a thermoplastic (or similar material containing the steps of: a. heating the plate-shaped object in the vicinity of said edge; b. engaging pressure members on the respective edge of said upper surface to form said chamfered edge by locally moving material from the upper layer in a downward direction while transferring a substantially corresponding amount of material from the article in a substantially lateral direction moved beyond the original boundary of the object; c. removing the amount of material displaced beyond the original boundary of the article, characterized in that during step b. counter-pressure members engage at strategic positions of the plate-shaped object to ensure that said amount of material of the object is correctly moved in said substantially lateral direction beyond the original boundary of the object. An optimum result can hereby be obtained.
    Preferably, said counter-pressure members are then arranged substantially opposite each other at the top and bottom of the plate-shaped object. However, depending on the specific characteristics of the method and depending on the properties of the materials of the plate-shaped object, the position of said counter-pressure members can be changed.
    Said counter-pressure members may comprise pressure rollers, pressure shoes or the like.
    In contrast to the manufacture of a chamfered edge using mechanical machining tools, the present method does not include the removal of material chips at the chamfered edge, but at a clearly below location. At the location of the beveled edge itself, the material is moved from the top layer, which results in a beveled edge of high quality. Moving the material is possible because the material is thermoplastic (or a material with similar properties, such as a plastic with a high content of thermoplastics) and is heated before being moved.
    It is noted that in the present invention the use of terms such as "above", "below" and so on relates to a horizontal position of the plate-shaped object in which the layer to be provided with the beveled edge is located at the top. During the practice of the method, however, it is possible for the plate-shaped object to assume a different position, for example with its "top layer" on the bottom.
    In an embodiment of the method according to the present invention, the plate-shaped object is provided with an upper layer with a thickness that is smaller than d and at least an adjacent layer of a thermoplastic (or similar) material, wherein during step a. At least one portion of the top layer and at least a portion of the adjacent layer is heated and wherein during step b. the top layer is bent substantially downwardly into and into the adjacent layer while material from the adjacent layer is displaced in the substantially lateral direction.
    Referring to a specific example of such a plate-shaped object, in particular a floor product (such as a floor tile or floorboard), the top layer is often a high-quality finishing layer (such as, for example, mainly consisting of PVC) that must impart optical and wear-resistant properties. As a result, such an upper layer is very expensive and its thickness should be reduced as much as possible to reduce its costs, and may be as small as 0.2 mm. If a plate-shaped object with such a thin top finish layer were provided with a deeper chamfered edge in a conventional manner (using the above-mentioned processing tools), the chamfered edge would extend into the adjacent layer which is generally different from the top layer and which would then become visible. This would adversely affect the attractive appearance of the beveled edge and the performance of the floor product, and in most cases this would require additional finishing steps, such as applying an optical lacquer layer and a layer to protect the adjacent layer against, for example, moisture . However, the use of the method according to the above-mentioned embodiment allows the manufacture of a beveled edge with a depth greater than the thickness of the top layer (which can be very thin to reduce the total cost of the article) without the adjacent layer (which often contains cheaper materials such as filling materials and recycled materials). The top layer is bent into the adjacent layer to form the chamfered edge, while at the same time material is moved from the adjacent layer. The displaced material of the adjacent layer will be removed during step c. be deleted. The final beveled edge has a perfect appearance with a perfectly formed continuous outer contour.
    It is then possible for the top layer to have a first glass temperature and the adjacent layer to have a lower second glass temperature, wherein heating takes place up to at least the second glass temperature during step a. As a result, during engagement with the pressure members on the respective edge of the upper surface, it is ensured that the material of the adjacent layer will be displaced and that the upper layer will only be bent inwardly without being displaced otherwise.
    In an alternative embodiment of the method according to the present invention, the plate-shaped object is provided with an upper layer with a thickness greater than d and at least one adjacent layer, wherein at least a part of the upper layer is heated during step a. during step b. material of the top layer is moved closer to the adjacent layer in the substantially lateral direction.
    Such an embodiment is useful when, for example, the adjacent layer is not thermoplastic and contains, for example, wood, wood-like materials, duroplast or duropiast-like materials. This adjacent layer will not deform during the execution of the method. However, because the top layer is sufficiently thick, material from this top layer can be moved sideways close to the adjacent layer to form the chamfered edge. During step c. this material coming from the top edge will be removed.
    The heating step can, inter alia, take place by infrared heating, by blowing heated air against the plate-shaped object or by placing a heated part against the plate-shaped object, such as a strip heated to at least 120 ° C or the like.
    It is possible that the pressure members comprise pressure rollers, pressure shoes or the like. Such pressure members will be positioned and formed for optimum engagement with the respective edge of the plate-shaped object. A plurality of pressure members can also be used for simultaneously engaging various (or opposite) sides of the plate-shaped object for manufacturing two (or more) beveled edges at the same time.
    In a special embodiment, the pressure members are also effective for heating the object. Thus, the pressure members can define the single heaters or define additional heaters.
    Furthermore, in one embodiment, it is possible for the pressure members to comprise multiple pressure members with different heating temperatures, for example for gradually heating the respective zone of the plate-shaped object.
    In an alternative embodiment of the method according to the present invention, after step c. performed an additional step of mechanically finishing the chamfered edge. For example, it is conceivable that as a result of material properties (e.g. springback) of the top layer, the exact manufacture of the chamfered edge is not entirely possible solely by the pressure members and that a final mechanical processing (such as by milling, sanding, cutting or the like) is still possible always needed.
    The method may also include other steps, such as a final step of cooling the chamfered edge or the additional step of profiling the respective edge of the plate-shaped object, for example for manufacturing connecting means.
    All steps are preferably carried out in a continuous manner while the plate-shaped object is transported parallel to its edge to be provided with the beveled edge. As a result, a high output can be obtained. However, it should be noted that the method can also be carried out step by step.
    When the method is carried out in a continuous manner, the plate-shaped object can be transported through a processing line by conveying means engaging surfaces of said plate-shaped object such as a conveyor belt, conveyor chain, drive wheels, rollers or the like. Furthermore, in order to reduce friction and to prevent damage to the plate-shaped object, it is possible that a protective air cushion is formed between the said transport members and the respective surfaces of the plate-shaped object, for example through the use of air nozzles.
    The method according to the present invention is particularly suitable when the top layer of the plate-shaped object contains a high content of PVC, for example up to 80% PVC. It should be noted that the present method is also applicable to articles that contain only one layer of thermoplastic material, for example PVC.
    In a second aspect, the present invention relates to a plate-shaped object with an upper surface which is provided with a beveled edge on at least one of the edges of said upper surface, which beveled edge is manufactured using the method according to the present invention.
    The invention is explained in more detail below with reference to the drawing, in which:
    Figure 1 shows a part of a cross-section of a plate-shaped object;
    Figures 2-7 show successive steps during the execution of a first embodiment of the method according to the present invention, and
    Figure 8 shows a step during the execution of a second embodiment of the method according to the present invention.
    Referring to Figure 1, a portion of a cross-section of a plate-shaped object, for example a floor panel, is shown on a large scale. To provide this floor panel with a beveled edge, it will be placed upside down (as shown in the present embodiment) with an upper layer 1 pointing down, and an adjacent layer 2 pointing up. The top layer can for instance contain a high content of PVC and is thermoplastic. The adjacent layer is also thermoplastic in this embodiment.
    Figure 2 shows how the floor panel 1,2 is transported upside down by a processing line (with stations for carrying out the steps described with respect to figures 2-7) by means of a conveyor which can be provided with a lower chain part 3 and a upper belt part 4. First, the conveyor leads an edge 5 of the floor panel (which must be provided with the beveled edge) past a heating element, in this embodiment an infrared heater 6. Positioning means 7 and 8 engage on opposite sides of the floor panel to position it in a correct position while the method is being performed.
    As a next step, after heating the floor panel according to the step carried out in Figure 2, the respective edge 5 of the upper surface of the upper layer 1 of the floor panel is engaged by pressure members 9 for forming the required chamfered edge by locally a quantity of material of the upper layer (indicated in Figure 3 by the dark area 5 ') in an upward direction while a substantially corresponding amount of material (indicated in Figure 3 by the dark area 10) of the adjacent layer 2 is moved in a substantially lateral direction beyond the original boundary of the panel. One or more counter pressure members 11 have been applied to strategic positions of the floor panel to ensure that said amount of material 10 from the adjacent layer 2 is correctly moved in said substantially lateral direction beyond the original boundary of the panel.
    As can be seen clearly from figure 3, the panel is provided with an upper layer 1 with a thickness that is smaller than the final depth d of the beveled edge and an adjacent layer (from a thermoplastic or similar material), wherein during the heating step at least a portion of the top layer 1 and at least a portion of the adjacent layer 2 are heated. During the movement of material, the upper layer 1 is bent substantially downwards and in the adjacent layer 2, while material (10) of the adjacent layer is moved in the said substantially lateral direction.
    Figure 4 shows the floor panel after moving the material. The beveled edge with depth d is substantially formed, but the displaced material 10 of the adjacent layer 2 still protrudes from the panel.
    According to Figure 5, the amount of material 10 that has been moved beyond the original boundary of the panel is mechanically removed, such as by milling, sanding, cutting or the like using a removal tool 12. During this removal, the floor panel is still supported by the positioning means 7.8.
    Referring again to Figure 4, it is visible that the outer surface of the chamfered edge is not completely straight, as may occur due to phenomena such as recoiling of the material of the upper layer 1. Therefore, if a completely straight outer surface is required, a finishing step can be made. as shown in Figure 6 showing a processing tool 13 that acts on said outer surface.
    Finally, figure 7 shows an additional tool 14 that will be used for profiling the side of the floor panel, for example for forming a connecting member (such as a part of a snap connection).
    Figure 8 shows a part of an alternative embodiment of the method according to the invention that can be used when the plate-shaped object is provided with an upper layer 1 with a thickness greater than d and an adjacent layer 2 which in this case does not have to be thermoplastic to be. In this embodiment, only a portion of the top layer needs to be heated during heating. When the respective edge of the upper surface of the upper layer 1 is engaged by the pressure member 9 to form said chamfered edge, material of the upper layer 1 adjacent the adjacent layer 2 is displaced in said substantially lateral direction and forms a quantity of material 10 which will then be removed (in accordance with Figure 5). The remaining steps are equivalent to the steps described with respect to the embodiment of Figures 1-7.
    The invention is not limited to the embodiments described above which can be varied within the scope of the invention as defined by the claims. Thus, it is also possible to provide a beveled edge in a plate-shaped object that comprises only a single thermoplastic layer. Furthermore, it is conceivable that more than one chamfered edge is manufactured simultaneously, for example on opposite sides of the object. Finally, it is noted that, although the plate-shaped object contains only two layers in accordance with the embodiments described above, such a plate-shaped object can also contain more layers, as is known per se in the field of floor products (such as floor tiles or floorboards).
    权利要求:
    Claims (22)
    [1]
    Method for manufacturing a beveled edge with a depth d on at least one edge of an upper surface of a plate-shaped object, wherein at least an upper layer of said plate-shaped object contains a thermoplastic (or similar) material, with the steps of: a. heating the plate-shaped object in the vicinity of said edge; b. engaging pressure members on the respective edge of said upper surface to form said chamfered edge by locally moving material from the upper layer in a downward direction while transferring a substantially corresponding amount of material from the article in a substantially lateral direction moved beyond the original boundary of the object; c. removing the amount of material displaced beyond the original boundary of the article, characterized in that during step b. counter-pressure members engage at strategic positions of the plate-shaped object to ensure that said amount of material of the object is correctly moved in said substantially lateral direction beyond the original boundary of the object.
    [2]
    Method according to claim 1, wherein said counter-pressure members are arranged substantially opposite each other at the top and bottom of the plate-shaped object.
    [3]
    Method according to claim 1 or 2, wherein said counter pressure members comprise pressure rollers, pressure shoes or the like.
    [4]
    A method according to any one of claims 1-3, wherein the plate-shaped object is provided with an upper layer with a thickness that is smaller than d and at least one adjacent layer of a thermoplastic (or corresponding) material, wherein during step a. at least a portion of the top layer and at least a portion of the adjacent layer are heated and wherein during step b. the top layer is bent substantially downwardly into and into the adjacent layer while material from the adjacent layer is displaced in the substantially lateral direction.
    [5]
    Method according to claim 4, wherein the top layer has a first glass temperature and the adjacent layer has a lower second glass temperature and wherein during step a. Heating takes place up to at least the second glass temperature.
    [6]
    . Method according to any of claims 1-3, wherein the plate-shaped object is provided with an upper layer with a thickness greater than d and at least one adjacent layer, wherein at least a part of the upper layer is heated during step a. and wherein during step b. material of the top layer is moved closer to the adjacent layer in the substantially lateral direction.
    [7]
    The method of claim 6, wherein the adjacent layer is not thermoplastic and, for example, contains wood, wood-like materials, duroplast or duropiast-like materials.
    [8]
    A method according to any one of the preceding claims, wherein the step of heating is by infrared heating.
    [9]
    The method of any one of claims 1-7, wherein the step of heating is by blowing heated air against the plate-shaped object.
    [10]
    A method according to any of claims 1-7, wherein the step of heating takes place by placing a heated part such as a strip or the like heated to at least 120 ° C against the plate-shaped object.
    [11]
    The method of any one of the preceding claims, wherein the pressure members comprise pressure rollers, pressure shoes or the like.
    [12]
    A method according to claim 11, wherein the pressure members are also effective for heating the object.
    [13]
    The method of claim 12, wherein the pressure members include multiple pressure members with different heating temperatures.
    [14]
    A method according to any one of the preceding claims, wherein after step c. an additional step is performed of mechanically finishing the chamfered edge.
    [15]
    The method of any one of the preceding claims, wherein step c. is carried out mechanically, such as by milling, sanding, cutting or the like.
    [16]
    A method according to any one of the preceding claims, with a final step of cooling the chamfered edge.
    [17]
    Method according to one of the preceding claims, with the additional step of profiling the respective edge of the plate-shaped object, for example for manufacturing connecting means.
    [18]
    A method according to any one of the preceding claims, wherein all steps are carried out in a continuous manner while the plate-shaped object is transported parallel to its edge to be provided with the chamfered edge.
    [19]
    A method according to claim 18, wherein the plate-shaped object is conveyed through a processing line by conveying means engaging surfaces of said plate-shaped object such as a conveyor belt, conveyor chain, drive wheels, rollers or the like.
    [20]
    A method according to claim 19, wherein a protective air cushion is formed between said conveying members and the respective surfaces of the plate-shaped object.
    [21]
    A method according to any one of the preceding claims, wherein the top layer of the plate-shaped object contains a high content of PVC.
    [22]
    A plate-shaped object with an upper surface provided with a beveled edge on at least one of the edges of said upper surface, said beveled edge being manufactured using the method according to one of the preceding claims.
    类似技术:
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    同族专利:
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    RU2012102808A|2013-08-10|
    AU2012200515B2|2015-03-19|
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    法律状态:
    2021-08-18| PD| Change of ownership|Owner name: FLOORING INDUSTRIES LIMITED, SARL; LU Free format text: DETAILS ASSIGNMENT: CHANGE OF OWNER(S), CHANGE OF LEGAL ENTITY; FORMER OWNER NAME: IVC BV Effective date: 20210723 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP11152885.7A|EP2481553B1|2011-02-01|2011-02-01|Method for manufacturing a chamfered edge and plate shaped object provided with such a chamfered edge|
    EP11152885|2011-02-01|
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