NL1029769C2 - Inlaid panel production method for decorative panels, uses computer controlled laser or water jet cutting to produce inlay and computer controlled milling device to cut out pattern in panel - Google Patents

Abstract

A pattern (2) is cut out of the panel (1) using a computer-controlled milling device and the metal inlay (3) for placing inside the cut-out space is made by a computer-controlled laser or water jet cutting method or by punching using a punch which has been made by either of these cutting methods. An independent claim is also included for a panel comprising a panel section and a metal inlay. A hardened filler layer and an expansion opening for the filler material are located beneath the inlay.

Description

Method for manufacturing panels with insert parts, panel comprising a panel part provided with an insert part.

The invention relates to a method for manufacturing panels with insert parts wherein a pattern is taken out in a panel part, an insert part is manufactured in accordance with the removed pattern in the panel part, and the insert part is inserted in the removed pattern of the panel part.

Such a method can be used for applying decorative motifs in panels for, for example, furniture and floors.

An existing method is known from US patent application US2005006019.

US2005006019 describes a method in which corresponding patterns are cut out with the aid of a computer-controlled laser cutting device in, on the one hand, a panel part of a relatively soft material and, on the other hand, in an insert part of a harder material. For this purpose the panel part is cut with a laser controlled by a computer so that an opening is formed by the panel part. The insert part is formed by cutting it out of a larger whole, for example a plate. The panel part is connected to an insert part in the same plane. The insert part and the panel part are then arranged and bonded to the base part. The whole is then subjected to a final treatment.

Although the known method produces good results, it also has a number of disadvantages:

The final panel consists of three pieces, namely the panel part in which an opening has been cut, the cut inlay part and the base part on which the whole is mounted, and thus this method is relatively complex and time-consuming and expensive. Moreover, the method used in which the panel part and the insert part are connected to each other limits the possible designs. In particular, designs with relatively thin and slender parts for insert parts are difficult to manufacture in this way because of the risk of breakage during processing. 1 0 2 9 7 6 9 2

Because the panel part consists of several pieces, the chance of the pieces becoming detached is relatively large.

In US 2005006019, two older methods are described in the introduction, namely a method in which a pattern is provided in a wooden panel by means of a milling cutter, which pattern is subsequently filled with a curable material. The cured material is applied in the milled pattern and cured. However, this method has the drawback that it allows only a fairly coarse pattern control. Moreover, the hardness is limited and the curing time-consuming and the process is laborious manual work.

A method in which cavities, in a negative and positive form, are etched by means of a laser in two panels. Subsequently, the panels are superimposed so that the cavities fit. A side is then sanded until the insert pattern is visible. This method is also known from the European patent application EP 1398177. This method is very laborious and can only be used for a limited type of insert patterns. It is difficult, if not impossible, to make straight lines. Virtually no surface is perfectly straight and when sanding is often slightly too much or too little sanded, so that what was originally intended as a straight line is ultimately formed as a waveform. Both of the aforementioned methods are described in US2005006019 as very laborious and unsuitable for mass production and current production standards.

It is an object of the invention to provide a relatively simple method of the type mentioned in the first paragraph suitable for mass production of panels with insert parts.

To this end, the method according to the invention is characterized in that a pattern is milled out in the panel part by means of a computer-controlled cutter, and a metal insert part is manufactured by means of computer-controlled laser cutting or water cutting, or by means of punching using a die-cutting mold manufactured by means of computer-controlled laser cutting or water cutting.

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The invention is based on the insight that, contrary to what is said in US 2005006019, computer-controlled milling achieves such a high quality of production that, in combination with the use of metal inserts that are laser-cut or water-cut or 10 punches, mass production of panels with high quality inserts and nevertheless great design flexibility is achievable. Metal inserts can be made, with no risk of breakage, in finer details and slimmer designs than wooden or stones or other brittle inserts. Metal can also be used in thinner thicknesses without the risk of breaking than wood or stone or other brittle materials. This opens up new possibilities, such as the use of insert parts in thin laminate parts. Moreover, metal has the advantage over wood that it does not contain a grain structure. A grain structure blurs straight lines. Where the grain structure touches the side of the insert, the human eye tends to follow the grain structure somewhat. This is in particular the case if a wooden insert part is laid in a wooden panel part. The different wood grain of the insert and panel sections create an optical illusion that makes a straight line appear oblique or wavy. The control of milling as well as cutting can be done by means of a computer program to such an extent that the metal insert parts fit into the milled patterns to such an extent that they can be fitted seamlessly into the patterns. Metal inserts, in contrast to stone inserts, moreover have a certain flexibility which they make eminently suitable for the method according to the invention and which also makes it possible, if necessary or desired, for the insert, without risk of breakage, or at least with a much less chance of breakage than when using wooden or stone insert parts, from the panel part.

It is noted that, due to the difference in panel and insert machining methods, the lines following the cutter and the water or laser beam during cutting are not identical. Firstly, the cutter mills on the inner line of the pattern and the water or laser beam cuts the outer circumference of the pattern in the insert. In addition, the materials and methods are different, so that the amount of material that is concealed differs and a correction applies for this.

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Because in the method according to the invention, unlike that known from US 2005006019, the panel comprises only two necessary parts, the panel and the method for manufacturing it is simplified. The use of metal inserts in a softer panel, for example a wooden panel, is not known from US 2005006019. Although various materials, including metal, are mentioned for use, the combination of materials according to the invention is neither described nor the combination of techniques.

The depth of the milled pattern in the panel part is preferably greater than the thickness of the metal insert and the bottom of the milled pattern is provided with a filling layer for inserting the metal insert. The use of a filling layer as a bottom layer makes it easier to detach the insert part from the panel part. By means of a sharp object, it is possible to get underneath the insert and remove the insert from the milled pattern 20, for example for maintenance or renovation.

Preferably, a filling layer is applied of a hardening material, in which the metal insert is glued and inserted and pressed. Pressing ensures that the surface of the insert part lies flush with the top of the panel part. The filling material subsequently hardens, as a result of which the insert part lies and remains flat with the panel part. Finishing operations such as sanding to level the surface are no longer necessary.

Preferably, the material of the filler layer expands during curing or excessive material is used as the filler layer, and the panel part is provided with an expansion opening for the filler material. By expanding the material or the abundant use of filling material, the filling layer connects very well to the insert and supports it very well. The expansion opening prevents the expanding material or the excess material from being able to push away the insert.

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The material of the filling layer preferably has an adhesive effect.

The insert part is preferably punched. Die cutting causes a slightly curved shape along the die edge. This form is often disadvantageous. In this case, however, this shape is favorable if the insert is inserted into the cartridge with the punching edge facing the panel portion and is brought together under pressure. The curved stand edge deforms on the bottom of the removed pattern in the panel part and contributes to locking the insert part in the panel part. The punching edge provides some clamping action.

These and further aspects of the invention are described below and illustrated with reference to the drawing.

15 In the drawing:

Figure 1 shows a method known from US 2005006019;

Figure 2 shows a further method known from US 2005006019;

Figure 3 shows a method according to the invention; Figure 4 shows an embodiment of the method according to the invention;

Figure 5 shows an embodiment of the method according to the invention;

Figure 6 shows a further embodiment of the method according to the invention;

Figure 7 shows a further embodiment of the method according to the invention;

Figure 8 shows an advantage of the method as illustrated in Figure 7;

Figure 9 shows an assembly of floor parts manufactured according to the method according to the invention;

Figure 10 shows a detail of an assembly of floor parts as shown in Figure 9.

The figures are not drawn to scale, the same parts are generally designated by the same reference numerals.

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Figure 1 shows a method known from US 2005006019. With the aid of a computer-controlled laser cutting device, corresponding patterns 2,3 are cut out on the one hand in a panel part 1 of a relatively soft material in the example of US 5 2005006019, on the other hand in a part of a harder material, which part is indicated in the figure by the dotted rectangle 4.

For this purpose, the panel part 1 is cut with a computer-controlled laser so that an opening 2 is formed in the panel part. The insert part 3 is formed by cutting out, also using a computer-controlled laser cutting device 10, a larger whole * for example a plate 4. The panel part 1 and insert part 3 are mutually connected in the same plane and the whole is then connected to a base part 5 connected, for example glued. The whole is then subjected to a final treatment. Steps A, B and C are therefore required to arrive at the end product, the panel with insert. The final panel consists of three pieces, namely the panel part 1 where an opening 2 has been cut, the cut inlay part 3 and the base part 5, and the manufacture thereof is relatively complex and time-consuming. Step B also limits the shape and materials that can be used. The insert parts and the panel part must have a reasonably large degree of thickness and sturdiness in order to be manageable and to be connected to each other, without risk of breakage or damage.

In this step B, fragile and / or insert parts with narrow parts cannot be used or are difficult to use without the risk of breakage and intervention of manual correction in the production process. Moreover, the technology used is relatively expensive. !

Because the panel part consists of several pieces, the chance of the pieces coming off is relatively large. The method is relatively expensive.

Figure 2 illustrates a method described in the introduction to US 2005006019 and also from EP 1398177. In this method, a cavity 2 and a corresponding protruding part 3 are formed in two parts 1 and 4 by means of laser ablation. The two parts 1 and 4 are placed on top of each other in such a way that protruding part 3 fits into recess 2. Then the two parts are together! connected, for example glued, and a layer of part 4 is removed, such that the surface of part 1, apart from the recess 2 provided with projecting part 2929, becomes visible again. This method produces a lot of waste and is very laborious.

It is difficult, if not nearly impossible, to make straight lines in natural material such as wood. It is true that straight lines can be made in parts 1 and 4, but with wood with a clear grain texture, virtually nothing is perfectly flat and the desired pattern is difficult to keep in shape while sanding is often slightly too much or too little sanded, so that what was originally meant as a straight line is eventually formed as a waveform. Inlay parts with narrow parts can even, under the force of the laser or during sanding, break or damage on the narrow part.

It is therefore rightly stated in US 2005006019 that this method does not lend itself well to mass production.

Figure 3 illustrates a method according to the invention. A pattern 2 is milled in a panel part 1 by computer-controlled cutter. Using either a computer-controlled laser cutting device, or a computer-controlled water-cutting device, or a computer-controlled laser cutting device or water-cutting device, a metal insert 3 corresponding to the pattern 2 is formed.

The invention is based on the insight that, contrary to what is US

2005006019 it is claimed that such a high production quality, production speed, accuracy and a low production price can be achieved by means of computer-controlled milling in the base panel that, in combination with the use of metal inserts, the claims from US2005006019 are valid by means of computer controlled laser cutting or water cutting or punching, mass production of panels with high quality inserts and nevertheless great design flexibility can be achieved. The control of milling as well as (laser or water) cutting can be done so accurately by means of a computer program that the metal inserts fit seamlessly into the milled patterns that the inserts even insert themselves into the patterns without adhesives and a gap between them the inserts and the panel in which the pattern has been milled is hardly visible with the naked eye.

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Comparison of figures 1 and 2 with figure 3 shows that the panel with insert is simpler in design, and fewer manufacturing steps are required. Yet a method is provided that is suitable for mass production and delivers high quality products. The method and material used for the insert make it possible to produce designs, in particular designs with insert parts that contain narrow pieces that cannot be produced with the existing method or can only be produced at high costs. The risk of breakage is reduced because fewer manufacturing steps are required, because a metal insert is less susceptible to breakage, especially for narrow sections. Such a narrow, vulnerable part is indicated, by way of example, in Figure 3 with 3a.

Metal inserts can, for the same strength, be made thinner than wooden or stones or other brittle inserts. As a result, the method according to the invention can be used for panels with a small thickness, such as, for example, laminate.

Figure 4 illustrates a preferred embodiment of the method according to the invention. The insert has been punched. Punching often causes a punching edge 6 in which the punched part, in this case the insert part 3, is slightly convex. This form is often disadvantageous. In this case, however, this shape is favorable if the insert is inserted into the pattern with the convex side facing the panel part and the walls of the removed pattern are removed at an angle. The cutting edge provides some clamping effect.

Figure 5 illustrates a preferred embodiment of the method according to the invention. Before insertion part 3 is applied in the pattern 2, a filling layer 7 is applied. In order to be able to apply the filling layer 7, the depth of the milled pattern is greater than the thickness of the insertion part 3. The filling layer 7 provides a number of advantages. It also makes it easier to remove the insert part from the panel part. This is particularly advantageous for maintenance and renovation. The material of the insert part is preferably harder than that of the panel part. This simplifies removal without damaging the insert. Moreover, this is more favorable for the embodiments shown above.

Figure 6 illustrates a preferred embodiment. The pattern is milled in such a way that the walls 2a, 2b of the milled pattern 2 make an angle with the surface in which the pattern is milled, whereby the opening becomes larger when viewed from the milled surface. The angle is preferably small, for example between 0.1 and 5 degrees. The insert part 3 is made such that it is exactly as large as the nominal opening of the cartridge. If the insert, is inserted and i | 5, the walls slightly deviate because the pattern is made in a panel part 1 of a softer material than the material of the insert 3. After the insert has been inserted, the walls of the milled pattern exert a clamping action on the inserted insert, which reduces the risk of loosening of the insert 3. This illustrates a first preferred embodiment.

Figure 7 shows a floor part with coupling elements 8a, 8b with which different floor parts can be interconnected. The invention is eminently suitable for the manufacture of panels, in particular floor parts, which comprise coupling elements. The known methods are not or less suitable for this because all floor parts in a floor must have the same after-treatment and thickness differences as a result of sanding are not desirable. Also, existing techniques do not provide for the use of floor parts with varying thickness and surface that are not flat. In addition, Figure 7 illustrates a preferred embodiment of the method. For applying the insertion part 3, the bottom of the opening 2 is provided with filling material. This filling material cures and fills the excess material that has been removed from the pattern in the panel part. The opening 2 is provided with an expansion hole 9. After the insertion part has been inserted, a compressive force F is exerted. This is possible, for example, by applying a weight, by means of a clamp, or by means of a press. The insertion part is held in a plane with the upper side of the panel part 1 by the use of excess filling material or by exponent filling material because the pressure force F carries away the excess filling material through expansion hole 9. The filling material ensures a smooth underlay that supports the insert almost perfectly. The expansion hole prevents the filler material from exerting too high an upward force on the insert during curing.

Figure 8 shows schematically that, due to the preferred embodiment of the invention shown in Figure 7, the provision of the insert has a positive influence on the panel as a whole. The panel part 1 often exhibits a certain curvature after manufacture or due to the natural action of the material used. The bottom of the milled opening is flat with respect to a reference surface of the milling machine, see part a of figure 8, but not due to the curvature of the panel part 1 itself relative to the upper surface of the panel part 1. The opening 2 is filled with a curable filler material 7 which fills the fully available space for curing in liquid form, see part b of figure 8. The insert part 3 is inserted and the whole is pressed on by force F on the flat surface, see part c of figure 8. The abundant use of the filling material 7 therefore fits almost perfectly on the underside of the insert 3 and supports this after curing. The excess material can escape through 10 expansion hole 9. The cured material fixes and stabilizes the panel part and the insert part in a flat form or at least in a form that is flatter than the original form, see part a of figure 8.

Figure 9 shows a joint pattern that extends over an assembly of a plurality of interconnected panels, for example a plurality of floor parts.

In particular in such embodiments, in which the insert part extends over several separate panels, it may be advantageous if a flexible filling layer is provided so that thickness and dimensional differences of the floor parts do not lead to undesirable dimensional differences in the pattern.

Figure 10 shows a detail of such an assembly. The floor parts are connected by means of coupling elements 8a and 8b. Although an edge is visible between the insert parts 3, the human eye draws an apparent line (indicated by a dotted line in Figure 10) between the insert parts 3. The fact that freezing causes the corners of the insert parts to form a slightly round shape benefit. The lack of pointed corners reduces the adverse effect of small shifts between the patterns with respect to this apparent line.

Briefly, the invention can be described as follows:

A panel (1) with insert parts (3) is manufactured by taking out a pattern (2) from a panel part 30 (1), manufacturing an insert part (3) in accordance with the removed pattern in the panel part, and the insert part ( 3) to be inserted in the removed pattern (2) of the panel part (1). The panel part (1) 1029769 11 is milled by means of a computer-controlled cutter, and a metal insert (3) is manufactured by means of computer-controlled laser cutting. or water cutting, or die-cutting using a computer-controlled laser cutting or water-cutting die.

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It will be clear that many variations are possible within the scope of the invention and that the invention is not limited to the examples given above.

The invention is particularly suitable for use with panel parts made of a material softer than the metal insert, and in particular for wooden panel parts. Wood can also be compressed wood. Furthermore, it is particularly suitable for panel parts made of fiber board, for example MDF or HDF (Medium or High Density Fiber) board.

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Claims (18)

1. Method for manufacturing panels with insert parts wherein a pattern (2) is removed in a panel part (1), an insert part (3) is manufactured in accordance with the removed pattern in the panel part, and the insert part (3) in the removed pattern (2) of the panel part (1) is inserted, characterized in that a pattern (2) is milled out in the panel part (1) by means of a computer-controlled cutter, and a metal insert (3) is manufactured by means of computerized laser cutting or water cutting, or by punching using a computer-controlled laser cutting or water cutting die. Method according to claim 1, characterized in that the depth of the milled pattern (2) in the panel part (1) is greater than the thickness of the metal insert (3) and that for inserting the metal insert ( 3), the bottom of the milled pattern is provided with a filling layer (7). Method according to claim 2, characterized in that the filling layer (7) has an adhesive and / or adhesive effect between the panel and the insert. Method according to claim 2 or 3, characterized in that a filling layer of a hardening material is applied, after which the metal insert is inserted and pressed during the hardening of the filling layer (7). 5. Method as claimed in claim 4, characterized in that the opening is provided with a filling layer of a material that expands during curing and the panel part is provided with an expansion hole (9). 6. Method as claimed in claim 2, 3 or 4, characterized in that the opening is provided with abundant filling material for the filling layer, after which the metal insert is inserted and pressed and the panel part is provided with an overflow hole (9). A method according to any one of the preceding claims, characterized in that the insert part is punched. 1 0 2 9 7 6 9 A method according to any one of the preceding claims, characterized in that the pattern is milled such that the walls (2a, 2b) form an angle with the surface of the panel part. Method according to claim 8, characterized in that the angle is between 0.1 and 5 degrees. 10. Method as claimed in any of the foregoing claims, characterized in that the panel part is provided with coupling elements. A method according to any one of the preceding claims, characterized in that the panel is a floor part. A method according to any one of the preceding claims, characterized in that the panel part is made of a material that is softer than the metal of the insert part. A method according to any one of the preceding claims, characterized in that the panel part is a wooden panel part or is made of fiber board. Assembly of panel parts provided with a divided pattern and provided with coupling elements manufactured according to the method according to one of the preceding claims. 15. Panel comprising a panel part (1) provided with an insert part (3), wherein the insert part is a metal insert part and underneath the metal insert part a cured filling layer (7) is provided and an expansion opening (9) for the filling material. Panel according to claim 15, characterized in that the panel part is made of a material that is softer than the metal of the insert. 17. Panel as claimed in claim 15 or 16, characterized in that the panel part is a wooden panel part or is made of fiber board. 18. Panel according to claim 15, 16 or 17, characterized in that it is a floor part. 30 1029769