EP1754581B1 - Method for manufacturing panels - Google Patents

Abstract

The panel production process produces panels from a large-surface initial board having long sides (11, 12) with locking battens (15, 16). The initial board has parallel grooves (4, 5) in its upper and lower surfaces. These are offset to form a breaking web in the board plane, along which the board is divided, leaving the projecting long battens in place for use in shaping the locking battens.

Description

The invention relates to a method for the production of panels for floors, wall or ceiling coverings.

As a floor covering as well as for wall or ceiling cladding are now often coverings of panels with various surface coatings and different decor and geometric configuration used.

For example, laminate flooring is widely used. A laminate floor panel consists of a panel panel made of fiber material, usually made of a high- or medium-density fiberboard on top of which a resinated decor paper is applied. The decor paper determines the appearance of the panel. The so-called overlay or the seal forms a special treated wear layer of paint, which gives the floor panels a high surface durability. On the underside of the panel plate, a so-called back-pull is applied. This serves the dimensional stability and the moisture barrier. Optionally, a footfall sound insulation can also be provided on the underside.

The production of the laminate floor panels as well as panels for the wall or ceiling cladding is carried out in a continuous flow process in which a large-scale base plate from a high- or medium-density fiber material receives the multi-layered layer structure with decorative paper, sealant and backing. Subsequently, the plate is divided into panels. Thereafter, the edges of the panels are profiled to form on their long sides and head sides locking strips. Mostly the locking strips are designed on the opposite edge sides of a panel as a tongue and groove. In a laid covering, the locking strips of adjacent panels engage each other.

The dividing of the panels from the large-scale output plate is done by a saw cut. Subsequently, the edges are reworked as mentioned and profiled to form the locking strips. The saw cut and the profiling inevitably lead to material losses. Therefore, a rationalization or optimization of the manufacturing process is desirable.

The US-A-2005/0160694 discloses a method for producing panels according to the preamble of claim 1, wherein in order to reduce waste material, the starting plate is provided at its top and bottom with parallel, offset grooves.

From the WO 2004/074597 A1 goes out a method for profiling of floor panels. These are cut out of a starting plate and then provided on the long sides with a tongue and groove profiling.

The EP 1 048 423 A2 shows a method and a machine for longitudinal profiling of panels. With this machine even complex tongue and groove profiles can be milled.

The invention has for its object to show a more rational process for the production of panels, which allows material and cost savings.

The solution to this problem consists according to the invention in a method according to the measures of claim 1.

The output plate is provided with an upper groove from its upper side and at least one lower groove from its underside, the upper groove and the lower groove being parallel and offset from one another. The output plate is then split. By the cut of the grooves remain projecting longitudinal strips along the longitudinal sides, which are used in the formation of the locking strips.

The crux of the invention is the measure that the upper groove and the lower groove are arranged offset from each other at a distance, so that between the grooves, a breaking web is formed and the output plate is then divided along the break web. Preferably, the division takes place in the horizontal direction parallel to the fiber material of the starting plate.

Since the individual panel sections are still connected after the production of the grooves through the rupture webs, it is possible to transport the starting plate as a whole and to transfer the profiling tool. This brings manufacturing advantages with it. Only during or before profiling the longitudinal strips on the long sides of the output plate is divided into individual panels.

Since the division is made so that the necessary cuts in the form of the grooves are performed in the areas that are removed during the profiling of the locking strips, the cutting loss resulting from the dividing the output plate is minimized. On a continuous saw cut is omitted according to the invention. As a result, the usual loss of material, which corresponds at least to the width of a saw blade, can be avoided in each division process in the longitudinal direction of the starting plate. Overall, the procedure according to the invention, depending on the panel width and profile of the locking strips, can expect up to 8% better utilization of the starting plate.

In principle, different starting plates with ready-applied surface coating can be used. Both known laminates or parquet as well as starting plates with a surface coating of linoleum, cork or direct paint, as well as with a surface of a textile Covering can be processed by the method according to the invention to produce panels for flooring, wall or ceiling coverings.

In particular, in the case of starting plates having a so-called aggressive surface, that is to say a highly wear-resistant or abrasion-resistant coating, it may be expedient to remove the surface beforehand in regions in the region of the upper groove to be produced. This is done with a milling tool. The milling tool makes a broach and clears the tread of the output plate. The width of the broach is hereby dimensioned so that it extends almost to the respective finished edge of the panels to be produced. The upper groove is then produced in the previously prepared broil (claim 3). In this way, a significantly longer service life of the milling or cutting tools can be achieved, which are used to produce the upper groove, since they only have to work in comparatively softer material, such as MDF. This measure also has an advantageous effect on the precision of the groove to be produced. The upper groove can be designed so that it is guided in front of the head side of the locking strip to be produced later in the profiling process, for example a spring.

In the context of a further advantageous embodiment of the invention, a first lower groove and a second lower groove is produced according to the measures of claim 4 on the underside of the output plate. This is done with horizontal distance from each other. The arrangement and configuration of the first lower groove and the second lower groove is made in adaptation to the profiling carried out in the subsequent operation of the longitudinal strips and the locking strips to be produced. The first lower groove and the second lower groove can basically be cut in a continuous process in parallel or with a time offset. The introduction of the first lower groove and the second lower groove can be done before the division process of the individual panels or subsequently. In practice, it is thought first to introduce the upper groove and the first lower groove in the output plate, then divide it and then, before profiling the longitudinal strips, bring the 2nd lower groove. In particular, the inner second lower groove serves as a guide groove for a profiling tool with which the longitudinal strips processed and the locking strips are made. In the first place, the use of a so-called double end profiler is intended here.

The first lower groove and the second lower groove can be cut to different depths, as provided by claim 5. This is done in adaptation to the profiling process to be performed and the profile of the locking bar to be produced.

According to the measures of claim 6, the grooves each have a slanted groove bottom. For the division process is advantageous if the groove bottom of the upper groove and the groove bottom of the lower groove in the same direction are chamfered (claim 7). This results in breaking the starting plate along the break web a kind of predetermined breaking line in the direction of the slopes in the groove bottom.

According to the measures of claim 8, the depth of a groove should correspond to 0.3 times to 0.6 times the value of the thickness of an initial plate. In practical experiments, the upper and lower grooves were slit to about half the thickness of the starting plate and then split. Here very good results were achieved. The upper groove and the lower groove can also be designed differently long. The placement and the depth of the grooves are made in adaptation to the configuration of the locking strips to be produced.

The horizontal distance between the upper groove and the lower groove is dimensioned according to claim 9 between 0.5 times to 3 times the width of a groove. The distance between the grooves is dimensioned in adaptation to the profiling of the locking strips so that a reliable division takes place along the breaker bar.

Figuren 1a bis 1c

in schematisierter Darstellungsweise den Vorgang zur Teilung einer Ausgangsplatte in drei verschiedenen Verfahrensstufen;

Figur 2

zwei nebeneinander liegende Paneelen mit der Darstellung eines Ausschnitts der Längsseiten in einem Vertikalschnitt;

Figur 3

eine Ausgangsplatte in der Draufsicht;

Figuren 4a bis 4e

den Vorgang zur Fertigung von Paneelen aus einer Ausgangsplatte in verschiedenen Arbeitsstufen;

Figuren 5a bis 5g

ein weiteres Ausführungsbeispiel des erfindungsgemäßen Verfahrens;

Figur 6

eine Ausgangsplatte bei der Herstellung der oberen und unteren Nuten in der Seitenansicht und

Figuren 7a und 7b

eine zusammenfassende Darstellung der Vorgehensweise bei der Herstellung der Nuten.

The invention is described below with reference to drawings. Show it:

FIGS. 1a to 1c

in a schematic representation of the process for dividing an output plate in three different process stages;

FIG. 2

two adjacent panels showing a section of the long sides in a vertical section;

FIG. 3

an output plate in plan view;

FIGS. 4a to 4e

the process for the production of panels from an output plate in different stages of work;

FIGS. 5a to 5g

a further embodiment of the method according to the invention;

FIG. 6

an output plate in the production of the upper and lower grooves in the side view and

FIGS. 7a and 7b

a summary of the procedure in the production of the grooves.

1a shows a section of a large-scale output plate 1. The output plate 1 consists of a high or medium compressed fiber material. On the output plate 1 is usually already the overlay and optionally also the return pull applied. The starting plate 1 is then divided in a continuous process first in the longitudinal direction and then in the transverse direction, so that individual panels are obtained.

To separate the starting plate 1 in the longitudinal direction, the starting plate 1 is, as seen in FIG. 1b, seen on the image plane, provided on its upper side 2 and on its underside 3 with parallel grooves 4, 5. The upper groove 4 and the lower groove 5 are arranged offset in the horizontal plane of the plate PE at a distance a from each other, so that between the grooves 4, 5 a break bar 6 stops. Thereafter, the output plate 1 is broken and divided along the breaker bar 6, as shown in Figure 1c. The resulting panels or panel strips are denoted by 7 and 8.

It can be seen that the grooves 4, 5 each have an obliquely running groove bottom 9, 10, wherein the groove bottom 9 of the upper groove 4 and the groove bottom 10 of the lower groove 5 are tapered in the same direction. The depth t of the groove 4, 5 corresponds approximately to half the thickness d of the output plate 1. The distance a between the upper groove 4 and the lower groove 5 corresponds to the width b of a groove 4, fifth

Due to the offset cut of the grooves 4, 5 remain after dividing the output plate 1 on the panels or panel strips 7, 8 along the longitudinal sides 11, 12 projecting longitudinal strips 13, 14 are. In a subsequent machining operation, the longitudinal sides 11, 12 are profiled and worked out of the material using the longitudinal strips 13, 14 locking strips 15, 16, as shown in Figure 2 can be seen. The locking strips 15, 16 on the opposite longitudinal sides 11, 12 are contour matched to each other and come in adjacent panels in a covering with each other.

In the figure 2, the profile of a panel or a panel strip 7 and 8 is shown hatched on its longitudinal sides 11, 12. The area shown in dashed lines between the panels 7, 8 has been removed after the parts of the output plate 1 in the profiling of the locking strips 15, 16.

Shown are also an upper saw blade 17 and a lower saw blade 18, with which the upper groove 4 and the lower groove 5 are produced. The upper groove 4 and the lower groove 5 extend parallel to each other and horizontally in the plane of the plate PE. It can be seen that the grooves 4, 5 are introduced into the region of the starting plate 1 which is not hatched in FIG. 2, that is to say in a region which is removed during the production of the locking strips 15, 16. In this way, a material savings can be achieved, since a continuous saw cut, in which the output plate 1 would be divided over its entire thickness d, is dispensed with.

It should also be noted that the underside of the panel strips identified in FIG. 2 analogously to FIG. 1b forms the cover layer or upper side of a finished panel 7 or 8.

FIG. 3 shows a finished coated starting plate 19 with a length l of 2,100 mm and a width b of 1,300 mm. The starting plate 1 is divided longitudinally into a total of five panels 20 which are profiled along their longitudinal sides 21, 22 and provided with locking ledges 23, 24, as shown in FIGS. 4a to 4e.

First, in a continuous process on the upper side 25 of the starting plate 19 with the aid of milling tools 26, broaches 27 are introduced. Here, the hard top 25 of the output plate 19 is removed in the region of the grooves 27. When considered together with the figure 7a it is clear that the top 25 is cleared in the region of a broach 27 almost to the finished edge 28 of a finished panel 20.

Subsequently, the output plate 19 is provided on its upper side 25 with an upper groove 29 and on its underside 30 with a lower groove 31. In this case, the upper groove 29 is produced in the previously produced broil 27. This is done in the continuous process by means of diamond saw blades 32, 33.

It can be seen that the upper groove 29 and the lower groove 30 are parallel to each other and offset in the horizontal plane of the plate PE at a distance a. Between the grooves 29, 30 in each case a breaking web 34 remains, so that the output plate 19 initially remains connected and so can be transported as a unit. The output plate 19 is then transferred to a profiling, in which the longitudinal sides 21, 22 of the panels 20 profiled and the locking strips 23, 24 are generated. For this purpose, the output plate 19 is divided along the break webs 34, which define a predetermined breaking point, as can be seen in Figures 4c and 4d. It can be seen that along the longitudinal sides 21, 22 projecting longitudinal strips 35, 36 remain. These are processed by means of a profiling tool, so that, using the material of the longitudinal strips 35, 36, the locking strips 23, 24, as can be seen with reference to the figure 4e, are produced.

Also in the explained with reference to Figures 5a to 5e and Figure 6 procedure for the production of panels is first on the top 37 of a Output plate 38 generates a broach 39 and the top 37 removed in regions. Within the broach 39, an upper groove 40 is introduced. Parallel to this, a first lower groove 42 is produced on the underside 41 of the output plate 38.

The upper groove 40 and the first lower groove 42 extend at a distance a to each other and are still connected in the process stage according to Figure 5d via a break web 43. In the next step (Figure 5e), the output plate 38 is divided along the rupture web 43, so that individual panels 44 arise on the longitudinal sides 45, 46 projecting longitudinal strips 47, 48 remain.

Before profiling the longitudinal strip 47 of a panel 44, a second lower groove 49 is produced on its underside 41. The second lower groove 49 extends at a horizontal distance a1 to the first lower groove 42, so that a vertical web 50 is formed between the first lower groove 42 and the second lower groove 49. The first lower groove 42 is cut slightly deeper than the second lower groove 49th

The longitudinal strips 47 and 48 are then profiled, so that on the longitudinal sides 45, 46 of the panels 44 locking strips 51, 52 are formed.

The second lower groove 49 forms the profiling a guide groove for a profiling tool, a so-called Doppelendprofilierer. In addition, the second lower groove 49 is used to produce an undercut on the locking bar 51, which forms a latching recess 53 for a front-side latching web 54 on the corresponding bottom-side latching tongue 55 of the locking bar 52.

The dashed lines to be recognized in FIGS. 5b to 5g are intended as auxiliary lines intended to clarify the position or configuration of the longitudinal strips 47, 48 relative to the later locking strips 51, 52.

FIGS. 6 and 7 a and 7 b show an overview of the position of the milling or sawing tools with respect to the locking strips 51, 52 formed on the finished panels 44.

The running direction of the starting plate 38 through the processing station for producing the broil 39 and the upper groove 40 and the lower grooves 42, 49 is indicated in Figure 6 by the arrow LR.

With reference to FIG. 7a and FIG. 5b, it is clear that in the production of the broach 39, the upper side 37 of the starting plate 38 is cleared by means of a milling tool 56 almost to the finished edge 28 of the panels 44. By means of the upper saw blade 57, the upper groove 40 is made in the broaching 39, this cuts the saw blade 57 immediately before the top surface 58 of the later formed on the locking bar 51 spring 59 along. By means of the two saw blades 60 and 61, the processing takes place on the underside 41 of the output plate 38 for producing the first lower groove 42 and the second lower groove 49th

In FIG. 7b, furthermore, the imaginary break line along the break web 43 formed between the upper groove 40 and the first lower groove 42, as shown in FIG. 5c, is drawn in and identified by SL.

Reference numerals:

1 -

starting panel

2 -

Top v. 1

3 -

Underside v. 1

4 -

groove

5 -

groove

6 -

breaking web

7 -

panels

8th -

panels

9 -

groove base

10 -

groove base

11 -

long side

12 -

long side

13 -

longitudinal bar

14 -

longitudinal bar

15 -

locking bar

16 -

locking bar

17 -

sawblade

18 -

sawblade

19 -

starting panel

20 -

panels

21 -

long side

22 -

long side

23 -

locking bar

24 -

locking bar

25 -

Top v. 19

26 -

milling tool

27 -

Räumnut

28 -

finished edge

29 -

upper groove

30 -

Underside v. 19

31 -

lower groove

32 -

diamond saw blade

33 -

diamond saw blade

34 -

breaking web

35 -

longitudinal bar

36 -

longitudinal bar

37 -

Top v. 38

38 -

starting panel

39 -

Räumnut

40 -

upper groove

41 -

Underside v. 38

42 -

1st lower groove

43 -

breaking web

44 -

paneling

45 -

long side

46 -

long side

47 -

longitudinal bar

48 -

longitudinal bar

49 -

2nd lower groove

50 -

vertical web

51 -

locking bar

52 -

locking bar

53 -

recess

54 -

Raststet

55 -

catch tongue

56 -

milling tool

57 -

sawblade

58 -

head face

59 -

feather

60 -

sawblade

61 -

sawblade

PE -

board plane

a -

distance

a1 -

distance

t -

Depth v. 4, 5

b -

Width v. 4, 5

d -

Thickness v. 1

LR -

direction

SL -

Line of weakness

Claims (8)

1. Method of manufacturing panels for floor, wall or ceiling coverings, the panels being split off from an initial board of large area and being provided with locking strips on their longitudinal sides, the initial board (1, 19, 38) being provided with parallel grooves (4, 5; 29, 31; 40, 42) on its top side (2, 25, 37) and on its underside (3, 30, 41), the top groove (4, 29, 40) and the bottom groove (5, 31, 42) running offset from one another in the board plane (PE) and the initial board (1, 19, 38) being split, such that projecting longitudinal strips (13, 14; 35, 36; 47, 48) remain along the longitudinal sides (11, 12; 21, 22; 46, 47), which longitudinal strips (13, 14; 35, 36; 47, 48) are used for forming the locking strips (15, 16; 23, 24; 51, 52), characterized in that the top groove (4, 29, 40) and the bottom groove (5, 31, 42) run offset in the board plane (PE) at a distance (a) from one another while forming a breaking web (6, 34, 43), and the initial board (1, 19, 38) is split along the breaking web (6, 34, 43).
2. Method according to Claim 1, characterized in that the top groove (29, 40) is produced in a clearing groove (27, 39), produced beforehand, on the top side (25, 37) of the initial board (19, 38).
3. Method according to Claim 1 or 2, characterized in that a first bottom groove (42) and a second bottom groove (49) are produced at a horizontal distance (a1) from one another on the underside (41) of the initial board (38).
4. Method according to Claim 3, characterized in that the first bottom groove (42) and the second bottom groove (49) are cut to different depths.
5. Method according to one of Claims 1 to 4, characterized in that the grooves (4, 5) have a sloping groove root (9, 10).
6. Method according to Claim 5, characterized in that the groove root (9) of the top groove (4) and the groove root (10) of the bottom groove (5) are sloped in the same direction.
7. Method according to one of Claims 1 to 6, characterized in that the depth (t) of a groove (4, 5) corresponds to 0.4 to 0.6 times the thickness (d) of the initial board (1).
8. Method according to one of Claims 1 to 7, characterized in that the horizontal distance (a) between the top groove (4) and the first bottom groove (5) is dimensioned to be between 0.5 to 3 times the width (b) of a groove.

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