EP4292831A1 - Device and method for thermomechanical surface structuring of a chamfer of a floor element and production line for producing floor elements - Google Patents

Abstract

The present invention relates to a device (1) for thermomechanical surface structuring of a bevel of a floor element (10), having a temperature control device (7', 7'') for heating the bevel and having a rotatable embossing element (3) for structuring the heated bevel, which has an end face (3 ') with a profiling (5).

Description

The present invention relates to a device for thermomechanical surface structuring of a bevel of a floor element. Another subject of the invention is a production line for producing floor elements. The invention further relates to a method for thermomechanical surface structuring of a chamfer of a floor element.

Such devices are used, for example, in production facilities for the production of floor elements. When installed, floor elements may not be arranged exactly aligned in height due to manufacturing tolerance deviations or as a result of joining errors. In order to avoid any tripping over the floor elements and to enable the floor elements to be walked on without impact, they are typically provided with chamfers, i.e. beveled surfaces, on their edges. In addition to other criteria, such as optical ones, chamfers meet the technical requirement of making transitions between joining edges of floor elements visually appealing and avoiding accidents.

Chamfers are typically made by milling so that they have a smooth surface. Chamfers can then be technically designed in a variety of ways. For example, they can be partially or completely coated. The coating agent is usually picked up from a container by a rotating transfer wheel. The floor element to which the application takes place is typically moved by a conveyor device relative to the transfer wheel. The transfer wheel transfers the coating agent to the respective bevel of the moving floor element. The application is usually carried out contactlessly using adhesion forces alone. The disadvantage is that the bevels produced in this way are designed in a single color and smooth and are visually and haptically different from the decorative side of the floor element - which typically has a grain or other two- or three-dimensional patterns.

The production of bevels, which not only meet optical requirements but also tactile requirements, is particularly technically demanding. Especially the manufacturing A combination of optical and haptic properties represents a technical challenge in order to produce high-quality flooring elements whose bevels come close to the decorative side in terms of look and feel.

Against this background, the task is to provide a device that enables simple production of bevels whose look and feel are similar to those of the decorative side of a floor element.

• mit einer Temperiervorrichtung zum Erwärmen der Fase und
• mit einem rotierbaren Prägeelement zum Strukturieren der erwärmten Fase, das eine
• Stirnfläche mit einer Profilierung aufweist, vorgeschlagen.

To solve this problem, a device for thermomechanical surface structuring of a chamfer of a floor element is used

• with a temperature control device for heating the bevel and
• with a rotatable embossing element for structuring the heated bevel, one
• Has end face with a profiling, proposed.

The device according to the invention has a temperature control device which initially heats the bevel of the floor element. The heating allows the material of the floor element to be deformed in the area of the bevel with less pressure. A rotatable embossing element can mechanically process and plastically deform the heated bevel. As a result of the mechanical embossing, a pattern can be pressed or embossed into a bevel surface. The embossing element has an end face on which a profiling is formed. The profiling determines the pattern to be produced on the bevel surface. The profiling can be designed in many different ways. It preferably has a negative of a desired relief, for example a wooden relief, so that the transition area between a central section of the floor element and the bevel is designed to be visually and haptically less distinctive, but rather more fluid. With the device according to the invention, high-quality floor elements can be manufactured automatically and easily, the bevels of which are adapted to the decorative side in terms of their look and feel.

The embossing element is preferably rotatable about an axis of rotation which is arranged parallel to the chamfer. The device particularly preferably comprises a drive for rotating the embossing element.

According to a preferred embodiment of the invention it is provided that the embossing element is designed as a disk, wheel or roller. Such an embossing element can have a rotationally symmetrical, in particular circular, cross section, so that uniform contact with the chamfer can be maintained during rotation of the embossing element. Furthermore, after a complete revolution of the embossing element, the pattern created as a result of structuring the bevel can be produced again. A repeating and reproducible pattern or relief can therefore be produced along an entire bevel.

A preferred embodiment of the invention provides that the temperature control device is designed separately from the embossing element. A temperature control device designed separately from the embossing element offers the advantage that the two functionalities in the course of thermomechanical surface structuring - heating (thermal) and embossing (mechanics) - can be separated from one another in the sense of a division of labor. Consequently, the two functionalities can be operated and optimized separately, i.e. without interaction of one functionality with the other. The temperature control device is preferably located upstream of the embossing element spatially or with respect to a direction of movement of the floor element. In other words, the bevel can first be heated or preheated and then embossed using the embossing element. The advance heating offers the advantage that an advantageous requirement for mechanical shaping - greater formability due to material softening - is met.

According to a preferred embodiment of the invention, it is provided that the temperature control device is set up to heat the embossing element in order to heat the bevel. The bevel of a floor element can be heated indirectly using the embossing element. In other words, the embossing element can be heated and the bevel can be heated by physical contact of the embossing element with the bevel. For example, the embossing element can be heated by contact with hot air, using a heat lamp or an infrared radiator. The chamfer can therefore be processed both thermally and mechanically through contact with just one component.

A preferred embodiment of the invention provides that the temperature control device is integrated into the embossing element. The integration of the temperature control device into the embossing element offers the advantage that a separate temperature control device can be omitted. Furthermore, an integrated temperature control device can enable a compact design of the device. For example, an electrically operated internal heater can be used as an integrated temperature control device. Alternatively or additionally, the embossing element can comprise a fluid channel through which a heated fluid flows. The embossing element and then the bevel can be heated by heat conduction.

Particularly preferred is an embodiment in which the device comprises a further temperature control device which is designed separately from the embossing element. In addition to the temperature control device integrated into the embossing element, a separate temperature control device can be used. With two temperature control devices, the bevel can be heated both before and during mechanical embossing and thus more effectively overall.

A preferred embodiment of the invention provides that the profiling is designed symmetrically with respect to a cutting plane of the embossing element. Preferably, the profiled end face of the embossing element protrudes from a virtual and annular base surface of the embossing element in radial directions of the embossing element. Said cutting plane can be arranged in such a way that it divides the annular base surface into two narrower, identical or mirrored annular partial surfaces that are half as wide as the base surface. The profiling can, for example, have semicircular elevations that are evenly spaced in a circumferential direction of the embossing element. Alternatively, the parallel offset elevations in the circumferential direction can be spaced unevenly in order to give the pattern to be created on the bevel a more natural or less technically constructed look. In this way, the bevel and the central section of a floor element can be more difficult to differentiate from one another. Individual elevations of the profiling can also have different lengths in the radial direction and/or their width in the circumferential direction of the embossing element and can therefore be pressed into the bevel at different depths and widths.

According to a preferred embodiment of the invention, it is provided that the embossing element is designed to be pivotable for embossing differently inclined bevels. The embossing element can, for example, be rotatably attached to a support unit that can be arranged on a base. Furthermore, it can be pivotable against a vertical axis of the carrier unit. Due to the pivotability of the embossing element, it can be arranged in such a way that a tangent on the profiled end face of the embossing element runs parallel to the bevel to be embossed. The device can therefore be adapted to the production of different floor elements and used flexibly for different bevel angles by pivoting the embossing element.

Another object of the invention is a production line for the production of floor elements with a coating device for coating a bevel of a floor element and with a device for thermomechanical surface structuring of the coated bevel of the floor element according to one of the previous configurations. In the production line according to the invention, the bevel can be coated and structured by the embossing element. A paint, particularly a water-based paint, can be used as a coating agent. The device can then be used to carry out a thermomechanical surface structuring of the bevel, in which case the coating agent in particular can be heated and embossed. Simultaneous heating and embossing of the coating agent and the bevel is also conceivable. Furthermore, the bevel can be preheated as well as heated during embossing. In addition, further advantages and technical effects mentioned in connection with the embodiments of the device explained above apply to the production line.

• wobei die Fase erwärmt wird und
• wobei die erwärmte Fase mit einem rotierenden Prägeelement strukturiert wird, welches eine Stirnfläche mit einer Profilierung aufweist.

Another subject of the invention is a method for thermomechanical surface structuring of a chamfer of a floor element,

• whereby the bevel is heated and
• wherein the heated bevel is structured with a rotating embossing element which has an end face with a profile.

With the method according to the invention, the same advantages and effects can be achieved that have already been described in connection with the device according to the invention for thermomechanical surface structuring.

The bevel can be heated before the bevel is structured with the embossing element. Alternatively, the heating can take place synchronously with the structuring or embossing of the bevel. Further alternatively, the heating can be carried out both before and simultaneously with the embossing, for example with several, in particular two, temperature control devices. A temperature control device integrated into the embossing element or designed separately from the embossing element or a combination of the two can be used as the heat source.

According to a preferred embodiment of the invention, it is provided that the bevel is coated, in particular painted, before heating. Coating the bevel before heating can enable a variety of design options for the floor element or its bevel. For example, the coating can be softened by applying heat and made three-dimensional by embossing. The bevel can also be coated multiple times, for example with two different colored paints, to create unique optical patterns as a result of the heating. By coating, especially painting, the bevel can be made more resistant to external influences. In particular, the coating can prevent penetration prevent moisture from entering a base body of the chamfer. Furthermore, a coating can at least reduce mechanical effects on the base body. For example, the base body can be at least partially protected from abrasive wear of the base body, in particular scratches.

A preferred embodiment of the invention provides that the floor element is moved at a first speed relative to the embossing element, with the embossing element rolling on the bevel without slipping. The floor element can be moved by the conveyor and relative to a stationary axis of rotation of the embossing element. The embossing element can rotate towards the bevel without slipping by rotating around its axis of rotation. A slip-free embossing of the bevel can reduce the friction between the floor element and the embossing element. By eliminating or at least significantly reducing friction, the drive energy for realizing the relative movement between the floor element and the embossing element can be reduced. In addition, the absence or minimization of friction can reduce any wear on the embossing element and therefore prevent repairs to and replacement of the embossing element and reduce maintenance intervals.

According to a preferred embodiment of the invention, it is provided that the floor element is moved at a first speed relative to the embossing element, with the embossing element rolling on the chamfer with slip. A relative movement between the floor element and the embossing element can cause frictional forces that can be used advantageously for the three-dimensional design of the bevel, optionally also a coating formed on the bevel. For example, as a result of the relative movement or the friction caused by the relative movement, material elevations can be caused from the surface of the chamfer: since the floor element on the embossing element - in the case that the first speed is greater than a circumferential speed of the embossing element - partially or superficially on the further movement is prevented, frictional forces can arise on the surface of the floor element or the bevel against the direction of movement of the floor element, which cause material to pile up from the bevel surface, as it were. In an alternative embodiment of the invention - in the case that the first speed is smaller than a peripheral speed of the embossing element - material from the bevel surface can be stacked in the direction of movement of the floor element. In both cases, a changed surface structure of the bevel can be created and optical and haptic differences between the decorative side of the floor element and the bevel can at least be minimized.

Fig. 1

schematisch eine Ausgestaltung der erfindungsgemäßen Vorrichtung während einer Oberflächenstrukturierung einer Fase eines Fußbodenelements in perspektivischer Ansicht;

Fig. 2

in einer Bruchkantendarstellung das Fußbodenelement aus der Fig. 1 in einer Draufsicht;

Fig. 3

ein Prägeelement der Vorrichtung aus der Fig. 1 in einer perspektivischen Ansicht; und

Fig. 4

das Prägeelement während der Oberflächenstrukturierung des Fußbodenelements in einer Schnittdarstellung.

Further details and advantages of the invention will be explained below using the exemplary embodiments shown in the figures. This shows:

Fig. 1

schematically an embodiment of the device according to the invention during a surface structuring of a chamfer of a floor element in a perspective view;

Fig. 2

in a broken edge representation the floor element from the Fig. 1 in a top view;

Fig. 3

an embossing element of the device from the Fig. 1 in a perspective view; and

Fig. 4

the embossing element during the surface structuring of the floor element in a sectional view.

The representation in Fig. 1 shows a device 1 for thermomechanical surface structuring of a chamfer 2 of a floor element 10. The floor element 10 is moved by a conveyor device, not shown, in a conveying direction R illustrated with an arrow. The bevel 2 is heated by a separate temperature control device 7 while the floor element 10 is being conveyed. A surface of the preheated chamfer 2 is then embossed or structured by means of a disc-shaped and rotating embossing element 3. For structuring the chamfer 2, a profiling 5 is formed on an end face 3' of the embossing element 3. The profiling 5 is designed as a negative of the desired surface of the bevel 2 and extends in particular in a radial direction of the embossing element 3. The profiling 5 can press into the preheated bevel 2 and deform it plastically.

In Fig. 2 is the floor element 10 from the Fig. 1 shown schematically in a top view. The floor element 10 is shown shortened in that a large part of the floor element 10 is not illustrated by two broken edges. The floor element 10 has a chamfer 2 on each of its edges, which was created by milling. The Fig. 2 shows the floor element 10 from the Fig. 1 from underneath. The top view of the floor element 10 in the Fig. 2 consequently shows one in the Fig. 1 lower side of the floor element 10 facing away from the viewer, which lies opposite the decorative side 11 of the floor element.

In Fig. 3 is the embossing element 3 of the device 1 from the Fig. 1 shown in perspective. The profiling 5 is formed on the end face 3' of the embossing element 3. The profiling 5 has point-shaped, circular or cylindrical elevations, which are arranged evenly spaced apart from one another in a circumferential direction of the embossing element 3. Semicircular elevations are formed between the circular elevations and extend in radial directions of the embossing element 3.

The sectional view in Fig. 4 can be seen as a snapshot of a section of the representation in the Fig. 1 be understood. The profiling 5 of the rotating embossing element 3 presses into the bevel 2 of the floor element 10, which is preheated by means of the temperature control device 7", and gives it a three-dimensional structuring. The bevel 2 is arranged on an edge of the decorative side 11 of the floor element 10.

Reference symbol:

1

contraption

2

chamfer

3

Embossing element

3`

face

5

Profiling

7

Temperature control device

10

floor element

11

Decor page

R

Direction of conveyance

Claims (13)

Device (1) for thermomechanical surface structuring of a chamfer of a floor element (10) with a temperature control device (7`, 7") for heating the bevel and with a rotatable embossing element (3) for structuring the heated bevel, which has an end face (3`) with a profile (5). Device (1) according to claim 1, characterized in that the embossing element (3) is designed as a disk, wheel or roller. Device (1) according to claim 1 or 2, characterized in that the temperature control device (7") is designed separately from the embossing element (3). Device (1) according to claim 1 or 2, characterized in that the temperature control device (7`) is set up to heat the embossing element (3) in order to heat the bevel. Device according to claim 4, characterized in that the temperature control device (7`) is integrated into the embossing element (3). Device (1) according to one of claims 4 or 5, characterized by a further temperature control device (7"), which is designed separately from the embossing element (3). Device (1) according to one of the preceding claims, characterized in that the profiling (5) is designed symmetrically with respect to a cutting plane of the embossing element (3). Device (1) according to one of the preceding claims, characterized in that the embossing element (3) is designed to be pivotable for embossing differently inclined bevels. Production line for the production of floor elements with a coating device for coating a bevel of a floor element and with a device for thermomechanical surface structuring Coated bevel of the floor element according to one of the preceding claims. Method for thermomechanical surface structuring of a chamfer of a floor element, whereby the bevel is heated and wherein the heated bevel is structured with a rotating embossing element (3), which has an end face (3`) with a profile (5). Method according to claim 10, characterized in that the bevel is coated, in particular painted, before heating. Method according to one of claims 10 or 11, characterized in that the floor element is moved at a first speed relative to the embossing element (3), the embossing element (3) rolling on the bevel without slipping. Method according to one of claims 10 or 11, characterized in that the floor element is moved at a first speed relative to the embossing element (3), the embossing element (3) rolling on the bevel with slip.

Images