RU2358076C1 - Construction panel with compressed edges - Google Patents

Construction panel with compressed edges Download PDF

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Publication number
RU2358076C1
RU2358076C1 RU2007134443/03A RU2007134443A RU2358076C1 RU 2358076 C1 RU2358076 C1 RU 2358076C1 RU 2007134443/03 A RU2007134443/03 A RU 2007134443/03A RU 2007134443 A RU2007134443 A RU 2007134443A RU 2358076 C1 RU2358076 C1 RU 2358076C1
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Russia
Prior art keywords
surface
edge
surface layer
characterized
flooring
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RU2007134443/03A
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Russian (ru)
Inventor
Дарко ПЕРВАН (SE)
Дарко ПЕРВАН
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Велинге Инновейшн Аб
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Priority to EP05003173A priority Critical patent/EP1691005B1/en
Priority to EP05003173.1 priority
Application filed by Велинге Инновейшн Аб filed Critical Велинге Инновейшн Аб
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Publication of RU2358076C1 publication Critical patent/RU2358076C1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02005Construction of joints, e.g. dividing strips
    • E04F15/02033Joints with beveled or recessed upper edges
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/04Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/01Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement

Abstract

FIELD: construction. ^ SUBSTANCE: scaffold board with locking system contains wood-fiber based core and surface layer. The surface layer is on the top of the core. The upper flat parts of surface layer constitute the covering surface and horizontal plane. The plane, which is perpendicular to horizontal plane lying next to external edge of the surface layer, is a vertical plane. The scaffold board has an edge section with surface lying under horizontal plane. The edge surface next to vertical plane is at some distance from the horizontal plane. That distance represents edge depth and exceeds the thickness of superficial layer. The scaffold surface and edge surface are implemented as a one-piece element made from the same material. Density of that core part which is under edge surface adjoining vertical plane and distanced vertically from edge surface, is more than that, adherent to core part located under scaffold surface adjoining the edge section at the same vertical distance from floor surface. ^ EFFECT: effective manufacturing process, improved design and resistant to galling. ^ 32 cl, 9 dwg

Description

The present invention relates to building panels, especially to floorboards, which have a wood fiber core, a surface layer and extruded curved edge sections. More specifically, the present invention relates to the locking connection of building panels with sections of compressed edges located below the surface of the panel. The present invention relates to panels with such edge portions and to a method for manufacturing such panels.

The present invention is particularly suitable for use in floating floors that are made of floorboards containing a wood fiber core with a surface layer and which are preferably connected mechanically by a locking system integrated with the floorboard. A flooring board with a mechanical locking system has a rather complex edge profile, and curved edge sections are more difficult to manufacture than traditional furniture parts.

The following description of the methods of the prior art, the problems of known systems, as well as the objectives and features of the present invention, therefore, by way of non-limiting example, will be directed primarily to this area and, in particular, to laminate flooring with mechanical locking systems. However, it should be emphasized that the present invention can be used for individual floorboards with separate locking systems, where the floorboards have a core and at least one surface layer and where these two parts can be formed by pressure applied to the surface layer. Therefore, the present invention can be applied, for example, to floorings with one or more wood surface layers superimposed on a wood fiber core. The present invention can also be used in building panels, for example wall panels, flow panels and flooring overheads, such as stake profiles, transition profiles, or trim profiles.

In the following description, the visible surface of the floorboard described is referred to as the “front side”, and the opposite side is referred to as the “back side”. "Horizontal plane" refers to a plane that extends along the outer planar parts of the surface layer on the front side. A “vertical plane" is a plane perpendicular to the horizontal plane and extending at the outer edge of the surface layer. “Up” means the direction to the front side, and “down” means the direction to the back side. “Vertical” means parallel to the vertical plane, and “horizontal” means parallel to the horizontal plane.

"Edge portion" means a portion of an edge located below a horizontal plane. "Flooring surface" means the outer flat parts of the surface layer located along a horizontal plane. "Edge surface" means the surface of an edge portion. "Locking system" means cooperative connecting means that mutually connect floorboards vertically and / or horizontally. "Mechanical locking system" means that the connection can be made without glue.

Laminate floorings and other similar flooring boards comprise one or more upper layers of decorative laminate, decorative plastic or wood veneer, an intermediate core of wood fiber or plastic based material, and preferably a lower balancing layer on the back of the core.

Laminate flooring usually contains a core of fiberboard 6–9 mm thick, an upper decorative laminate layer and a lower balancing layer 0.1–0.6 mm thick made of laminate, plastic, paper or the like. Thicker laminate flooring with a thickness of 12-16 mm and more can also be produced. Such floorings have improved soundproofing properties. It is also possible to produce very thin floorings with a thickness of 3-6 mm. Such thin flooring can be used in rooms with underfloor heating, as a thin flooring panel more effectively passes heat to the surface than traditional flooring panels. The surface layer gives the floorboards the required appearance and wear resistance. The core provides stability, and the balancing layer protects the flooring panel with changes in relative humidity throughout the year. The flooring is floating, i.e. without glue, and is produced on an existing subfloor. Conventional solid flooring boards of this type in floating floors are usually joined by means of adhesive tongue and groove joints.

In addition to such traditional floorings, flooring boards were developed that did not require the use of glue and were connected mechanically by the so-called mechanical locking systems. These systems contain locking means that lock the boards horizontally and vertically. Mechanical locking systems can be formed by core processing. Alternatively, the details of the locking system can be formed from a separate material and integrated with the floorboard, for example, connected to the floorboard during its manufacture.

The most common core material is high density fiberboard with high density and high stability, which is commonly referred to as HDF (High Density Fiberboard). Sometimes, medium density fiberboard (MDF) is used as the core. DVPVP and DVSPP contain crushed wood fibers, which are connected with binders to sheet material.

Laminate flooring and many other floorings with a surface layer of plastic, wood, veneer, cork, etc. produce several technological operations. As shown in figa-1d, a surface layer and a balancing layer are made by separate operations, which are then connected to the core material, for example, by gluing a prefabricated decorative layer and a balancing layer to the fiberboard. Such a manufacturing process is applied when the flooring panel has a surface of a decorative high pressure laminate (HPL), which is produced in a separate operation, where a plurality of sheets of paper impregnated with a thermosetting resin, such as melamine and / or phenol, are pressed under high pressure and at high temperature.

However, at present, the most common method of manufacturing a laminate flooring is the direct pressing laminating method (LDP), where both the production of the decorative layer of the laminate and the fastening to the fiberboard are carried out by the same technological operation. One or more sheets of paper impregnated with a thermosetting resin, such as melamine or similar types of resins, are applied directly to the board and pressed together under pressure and at high temperature, without any bonding.

On figa-1d shows how the flooring is made of laminate according to known technology. Typically, the above-described methods produce an element (3 in FIG. 1c) of the flooring in the form of a large laminated board, which is then sawn into several separate panels (2 in FIG. 1c) of the flooring, from which then boards (1 in FIG. 1d are made by machining) ) flooring. The edges of the flooring panels are individually machined to produce flooring boards with mechanical locking systems at the edges. Edge processing is performed on complex milling machines where the floor panel is precisely positioned between one or more chains and a tape or similar element to move with high speed and with great accuracy past several milling heads equipped with diamond or metal milling cutters that process the edge of the floor panel. Using several milling heads, it is possible to form a complex profile with a speed of more than 100 m / min and with an accuracy of ± 0.02 mm.

The upper edges of the floorboards in most cases are very sharp and perpendicular to the floor surface and extend in the same plane as the floor surface.

Laminate floorings have recently been developed with decorative grooves or chamfers at the edges that look like a real gap or chamfer between solid wood flooring elements such as planks or parquet.

It is known that such edges can be made in several ways.

In recent years, laminate floors, which are an imitation of stone, tile, etc., are becoming more widespread. It is known that the method that is used to make decorative edges of such floorings can also be used to make edge sections that look like gaps in solid wood floors . This is shown in FIGS. 2a and 2b. The starting material is decorative paper with a printed edge, impregnated with melamine resin. With such an operation, uncontrolled swelling occurs. In the subsequent lamination, decorative impregnated paper is placed on the core and lamination is carried out using a relief metal plate, which forms a recess 20 in those parts of the flooring element 3 on which an edge section is to be formed. This is shown in FIG. 20a. The result is a floor element 1, 1 ′, on the front side of which there is a depressed or embossed pattern corresponding to the desired edge sections between the floorboards, as shown in FIG. 2b.

With this manufacturing method, a number of problems arise, which are primarily associated with the difficulties in positioning decorative paper and metal plates during lamination and with the difficulties in positioning the flooring element and flooring panels during subsequent sawing and edge processing. The result is a floor panel with edge sections, in the structure and design of which there are significant and undesirable deviations, as shown in Fig.2b. Another problem is that with this method it is possible to apply textures with a depth of less than 0.2 mm, which cannot be made deeper than the thickness of the surface layer. Another disadvantage is that, although the edge is below the surface of the flooring, it is sharp and parallel to the surface. The possibilities of using such a traditional technology for the production of extruded edge sections in the BOB panels in the form of, for example, a bevel or a complex curved shape were analyzed and evaluated. Some findings are described below and shown in FIG.

It is possible to use decorative paper having only a wood pattern, and this is advantageous since the problem of positioning the pressing plate and the printed decorative edge portion can be avoided. This method, however, has several disadvantages. It is very difficult to form an edge with an ED depth of more than 0.2 mm, which refers to the same order of magnitude as the thickness ST of the surface. The maximum angle AN that can be achieved is less than 10 °. Productivity will be insufficient, as the pressing cycle time and pressing pressure should be increased. Larger corners and deeper embossing increase the risk of paper tearing during production. In addition, the flooring element with recesses will be very difficult to position for subsequent sawing and milling. Significant undesirable deviations in the width EW1, EW2 of the edges of 0.3-0.5 mm appear. Adjacent edges and recesses 20, 20 ', which should be in contact with each other, will not be located at the same height. In addition, the surface layer of the laminate will be compressed, a particularly transparent superimposed wear-resistant layer 33, which is located above the printed decorative paper. All these problems are exacerbated if the traditional width of the floorboard, equal to 200 mm, is reduced to 150 mm, or 120 mm, or to less than 100 mm, as the number of recesses increases. For most tasks, this will require an increase in pressure from 300 N / cm 2 to 600 N / cm 2 or even 800 N / cm 2 . Significant investments will be required in new and more expensive pressing equipment and embossed metal plates, especially if it is necessary to produce flooring boards of different widths or lengths.

2c and 2d show another method. The decorative edge portion can be made by processing the edges of the floor panel 1, 1 ′. Then, lamination and sawing of the flooring element 3 can be carried out without any special leveling requirements, and there is no swelling problem. The decorative and embossed edge portion can be formed by a part of the decorative surface layer removed so that the reinforcing layer of the laminate becomes visible (Fig. 2d). Alternatively, the core 30 itself can be used to create a decorative embossed edge portion. This is shown in figa. From the areas that should form the embossed edge portion 20, the surface layer is removed and the core 30 is exposed. The decorative groove can be made only on one edge, as shown in figa. The main disadvantage is the impossibility of creating a pattern and structure that coincide with the surface layer. Therefore, it is impossible to form a portion of the edge that looks like a chamfer in a surface layer of solid wood.

The most common method is shown in fig.3b. Part of the edge portion of the floorboard 1, 1 ′ of the flooring is made in the form of a bevel 20, which is then closed in a separate operation with a separate material, for example, a film, a plastic strip, or it can be colorized, applied, etc. Such additional materials complicate and cost the process, and it is impossible to make an edge section with the same pattern and structure as the flooring surface. Such an edge portion has significantly lower abrasion resistance and worse moisture resistance than the floor surface. This production method is rather slow and requires several application devices so that the speed corresponds to the speed of modern lines producing laminate flooring.

Another method is shown in figs. The edge portion 20 is formed of a separate material that is inserted or extruded into the groove. This method has the same disadvantages as described above.

3D shows that the well-known postforming method used for furniture parts can produce rounded edge portions 20. The post-formed HPM laminating surface 31, which is so flexible that it can form after the manufacture of the laminated sheet, can adhere to the already processed floorboard 1. In the second step, the edge can be heated and the laminate bent and glued around the edge area. Such a method would be very complicated and expensive, since it is necessary to laminate separate flooring panels, and it is not used for laminate flooring. In theory, of course, you can use the BOB technology and directly compress decorative paper and the surface layer on the floor panel with curved sections of the edges. Even in this case, the press will have to submit individual flooring panels individually, which will lead to a sharp decrease in productivity.

The principles of the present invention relate to the edge sections of building panels and are intended to overcome one or more of the limitations and disadvantages of the prior art.

These and other objectives of the present invention are achieved by floorboards and methods of their production, having the characteristics given in the independent claims. The dependent claims define particularly preferred embodiments of the present invention.

The main objective of the present invention is the creation of building panels, especially floorboards, with curved sections of edges made in one with the surface layer, which can be produced more efficiently than products currently available on the market.

An additional object of the present invention is to provide such panels with edge portions that have improved design and abrasion resistance.

To achieve these objectives, according to the first principle of the present invention, there is provided a flooring board with a locking system, a wood fiber core and a surface layer located on the upper side of the core. The outer flat parts of the surface layer form the flooring surface and the horizontal plane. A plane perpendicular to the horizontal plane and extending at the edge of the surface layer forms a vertical plane. The floorboard has an edge portion with an edge surface that is located below the horizontal plane. The edge surface of the vertical plane is located at a distance from the horizontal plane, which forms the depth of the edge and which exceeds the thickness of the surface layer.

The surface of the flooring and the surface of the edge are made as a whole from one material. The part of the core at the edge portion under the edge surface adjacent to the vertical plane and located at a vertical distance from the edge surface has a higher density than the part of the core that is under the flooring surface near the edge portion and at the same vertical distance from the flooring surface .

A curved edge portion can be formed on only one edge, on two opposite edges, or on two pairs of opposite edges. Alternatively, an edge portion may be formed in panels having more than 4 edges.

The most effective is production, where the panels have curved edges according to the first principle of the present invention on two opposite, preferably long edges, if the floorboards are rectangular. Short edges can be traditionally straight. The short edges may also have at least one portion located below the surface and formed in any other way, such as described above and shown in figa-2e, 3a-3d, 6a-6b or 8.

Flooring boards with a wooden surface often have beveled or curved edges, which on long edges differ in shape and surface structure from short edges. The main reason for this is the different orientation of the fibers on long and short edges. In addition, various production methods are used to obtain them, which create a different appearance. It has been found that multilayer flooring boards can be produced more efficiently and with a design very close to wood, if the surface of the long edges is made different from the surface of the short edges.

According to a second principle of the present invention, there is provided a rectangular flooring board comprising pairs of opposing long and short edges, a mechanical locking system on at least one pair of edges, a wood fiber core and a laminated surface layer located on the upper side of the core. The outer flat parts of the surface layer form the flooring surface and the horizontal plane. Flooring boards at long edges and at least one of the short edges have areas with surfaces that are located below this horizontal plane. The long edge portion contains a material different from the short edge material.

According to one preferred embodiment of this second principle, the floorboard has one pair of long edges with a portion according to the first principle. On one short edge, the floorboard has a portion from which the surface layer of the laminate is removed, and a core based on wood fiber, for example, fiberboard, is painted or impregnated, for example, with a chemical based on oil.

According to a third principle of the present invention, there is provided a method of manufacturing a floorboard with a locking system, a wood fiber core and a surface layer located on the upper surface of the core. The outer flat parts of the surface layer form the flooring surface and the horizontal plane. The floorboard has an edge portion with a surface that is located below this horizontal plane. The method comprises the steps in which:

- apply a surface layer to the core to form a flooring element;

- cut the flooring element on the flooring panel;

- apply pressure to the surface at the edge section of the flooring panel so that the core under the surface layer is pressed and the surface layer is constantly bent to the back side.

According to a second aspect of the second principle of the present invention, there is provided a method of manufacturing a building panel with a wood fiber core and a surface layer located on the upper side of the core. The outer flat parts of the surface layer form the surface of the panel and the horizontal plane. The panel has an edge portion with a surface that is located below this horizontal plane. The method comprises the steps in which:

- apply a surface layer to the core to form a building element;

- cut the building element into building panels;

- apply pressure to the surface at the edge of the building panel so that the core under the surface layer is pressed and the surface layer is constantly bent to the back side.

The present invention can be used to obtain curved or beveled edge sections in panels of different widths, especially in narrow panels, as well as in very thick (12-16 mm) and thin (3-5 mm) laminate panels, as described in the introduction. Such thin and thick panels are not currently manufactured. The manufacturing equipment and method of the present invention is much easier to adjust to panels of different sizes and thicknesses than traditional pressing and postforming technologies.

The invention is illustrated in the drawings, which represent:

Figa-d is an illustration of the various stages of the production of flooring boards according to known technology.

Figa-e is an illustration of methods for forming sections of edges according to known technology.

Figa-d - examples of different methods of manufacturing sections of the edges of the prototype.

Figa-d - forming a portion of the edge by pressing of the present invention.

5a-c show various properties of a convex curved edge portion of the present invention.

Figa, b - alternative methods of formation according to the variants of the present invention.

7 is a profile profile according to the present invention.

Fig. 8 is an edge portion with a curved edge surface.

Fig.9 - flooring board with edge surfaces on the long and short sides, containing different materials.

On figa-c shows four stages of manufacturing floorboards according to one variant of the present invention. Fig. 4a shows two opposing edges of two substantially identical floor panels 2, 2 ', intended to be connected to each other by a mechanical locking system. The floorboards have a surface layer 31, for example, of a high density laminate, a direct compression laminate or wood veneer, a core 30 made of fiberboard and a balancing layer 32. As shown in FIG. 4b, an edge groove 16, 16 'and a part are formed on the upper side of the edge the surface layer 31 is removed. This can be done in a separate operation or during sawing of the flooring element 3 on the flooring panel 2. If the surface layer is a laminate, at least a portion of the edge groove 16, 16 ′ and the surface layer 31 next to the edge groove 16, 16 ′ are preferably heated with a suitable heating device H, for example a heating nozzle that blows out a uniform flow of hot air, infrared radiation, microwaves , high frequency, contact heating, laser or other known method. The temperature should exceed 100 ° C. The preferred temperature is 150-200 ° C. In many cases, a temperature of about 170 ° C gives the best results. For the surface layer 31, a laminate of normal quality that does not have a particular ability to postform can be used. However, production efficiencies can be enhanced by thermosetting resin modifications similar to those used in postforming laminates. If the surface layer is wood veneer, heating is preferably not required. The floor panel preferably has a base surface 17, 17 'that can be used to correctly position the floor panel during the formation of the edge portions and the locking system. As shown in FIG. 4 c, the edge portion 20, 20 ′ is then pressed by a pressing tool TO, which is preferably heated to the same temperature as described above. The pressing member may be a wheel and / or pressing shoe or the like having a profile that preferably matches the desired edge profile. To form an edge section, you can use several tools that are used in several stages, for example, on one long edge, on both long edges or on a short, and then on a long edge. Of course, short edges can be formed in front of long ones, and several floorboards can be processed on the same equipment. The wheels can have a different design and therefore allow the embossed portion of the edge to be formed. Such an edge portion may also have a random or synchronized structure. Edge pressing can be a continuous operation in which the floorboard, for example, is moved relative to a fixed tool. Of course, the board can be stationary, and the tool can move relative to the board. Other alternatives are possible. The hem can also be formed by a traditional pressing operation. This method is especially useful for short edges and allows you to accurately form the corner sections. When compressed, the fibers of the core will be constantly compressed, the orientation of the fibers will change in most cases, and the density at the edge portion 20 will increase. If the surface layer is a laminate, essentially in most cases a strong compression of the laminate will not occur. In some core materials, it may be difficult to detect a change in fiber orientation. However, the increased density can be measured with great accuracy. The edge portion 20 will be significantly stronger than the traditional beveled edges in the laminate flooring. Abrasion resistance will be similar to the surface of the floor, and the visible edge areas will have the same design and structure as the surface of the floor. The upper parts of the core 30 under the surface layer 31, which is melamine impregnated in the LPP flooring and glue in the LVD flooring, support the laminate surface layer 31 during bending and increase the flexibility of the laminate layer. The advantage is that you can use a thermoset decorative laminate of the usual quality, which is quite brittle. HDF is particularly suitable for such permanent compression molding of the present invention, since the fiber structure and binders that are used in HDF are ideal for this purpose.

As shown in FIG. 4d, a mechanical locking system with a tongue 10 and a groove 9 for vertical locking and a strip 6 with a locking element 8 and a locking groove 12 for horizontal locking can be easily formed and positioned with high accuracy relative to the pressed edge portion 20, 20 '. In this embodiment, the compression molding of the edge portion 20, 20 ′ is performed on the floor panel 2, from which the floor board 1 is then obtained. The advantage is that the formation of a mechanical locking system can be performed with high accuracy and the formation by pressing does not change the profile size, which in this embodiment is mainly the tongue 10 and the groove 9. The test production showed that tolerances of 0.1 mm or less can be obtained , which is much better than what can be obtained by known technologies. Of course, it is possible to form sections 20, 20 'on the floorboard after processing the edges, but this is more complicated, and the pressing possibilities in this case are more limited. In most cases, additional machining will be required to form the outer top edge.

Fig. 5a shows a section of the edge of the panel of the present invention. In this preferred embodiment, the flooring panel 1 has a BOB surface layer 31 with a surface thickness ST and an outer edge 51. The upper flat part of the surface layer 31 forms a horizontal plane HP and a flooring surface 33. A plane perpendicular to the horizontal plane and located at the outer edge 51 forms a vertical plane VP. The convex curved portion 20 of the edge, which is located below the horizontal plane HP and extending to the vertical plane VP, has an edge width EW measured parallel to the horizontal plane HP and an edge surface 50. The edge portion 20 is considered to be curved convexly if at least some of its parts are convex and the remaining parts are straight, as shown in FIG. 5a. The edge portion 20 has an edge depth ED measured vertically from the horizontal plane HP, which is equal to the distance SD from the horizontal plane HP to the outer edge 51 in the vertical plane VP. As shown in FIG. 5 a, the fibers in the edge portion 20 were compressed, and the orientation of the fibers changed so that the fibers bent in the same direction as the surface 50 of the edge portion 20. The tangent TL1 to the curved portion 20 of the edge drawn at the vertical plane has a larger angle AN2 to the horizontal plane than the tangent TL2 drawn at some distance from the vertical plane, for example, at a distance of 0.5 * EW. The present invention allows the formation of edge portions where tangent TLs form an angle of more than 10 °. It is even possible to obtain edge portions where the AN angles exceed 15, 20, 30, or even 45 °.

Several ratios are advantageous in obtaining the edge portion 20 of the present invention.

- The depth of the ED edge is preferably greater than the thickness ST of the surface layer. In the most preferred embodiment, the depth of the ED edge should be 2 or even 3 times greater than the thickness ST of the surface layer. This method allows you to form a section of the edge 20 with a depth of ED, 10 times the thickness ST of the surface layer.

- The width EW of the edge should preferably be greater than the depth ED of the edge. In the most preferred embodiment, the width EW of the edge should be 2 times greater than the depth ED of the edge.

- The depth ED of the edge should preferably be greater than 0.1 times the thickness T of the floorboard.

- The thickness ST of the surface layer 31 should be - 0.1-0.01 of the thickness T of the flooring board.

- The tangent TL to the edge portion located at the vertical plane VP must have an angle to the horizontal plane exceeding 10 °.

These ratios can be used independently or in combination on one edge or, for example, on long and short edges. Long edges, for example, can be made with more rounded portions of the edges than short edges. A preferred combination is one where the ED depth of the edge is greater than the thickness ST of the surface layer and the tangent NL to the portion of the edge portion 20 has an angle greater than 10 °.

Fig. 5b shows the density profile D in part AA of the flooring board 1 that has not been pressed, and Fig. 5c shows the density profile D at the portion BB of the pressed edge of the same flooring board 1. The density profile can be measured with very high accuracy by a gamma ray beam. The distance between the measuring points can be as low as 0.04 mm. In this example, the surface layer 31 of the laminate, having a thickness of about 0.2 mm, has a density of about 1300 kg / m 3 . Under the surface layer 31 is a portion 52 of the core, which was directly impregnated with melamine during lamination and where the density varies between about 1200-1000 kg / m 3 . Below this portion 52 of the core, there is another portion 53, where the density is slightly higher than in the middle of the core 30. The average density is shown by line AD. It should be emphasized that the pressing of a material based on fiberboard always leads to an increase in density.

Fig. 4d shows an alternative method. Two test samples S1 and S2 with the same thickness ST were taken at the edges, and their weight was measured. If the weight per millimeter is the same, this is a good indicator that the material was not removed and the edges were compressed. The thickness of the sample can be, for example, 2.44 mm, and the length of the sample is 20 mm along the joint. Sample S1 may have a SW width of 3.46 mm and sample S2 of 3.04 mm. The weight of sample S1 is 0.167 g and the weight of sample S2 is 0.143 g. S1 has a weight per millimeter of length 0.167 / 4.46 = 0.048 g and sample S2 is 0.143 / 3.04 = 0.047 g. The reason for this small difference is before all in that, in sample S1, there is a slightly larger surface layer with a higher density than HDF, because of its curved shape. Similar tests on a panel where the surface layer was laminated to an edge rounded by machining showed that S1 has a weight of 0.062 g / mm and Sample S2 has a weight of 0.071 g / mm. This is a good indicator that the core material has been removed before being pressed and not compressed according to the principles of the present invention.

Fig. 5c shows the density profile in the pressed portion BB of the edge portion 20. A portion of the core 30 in the edge portion adjacent to the vertical plane VP and at a vertical distance SD from the surface layer 31 has a higher density D than the portion of the core that is below the flooring surface adjacent to the edge portion 20 and at the same vertical distance SD from the surface layer 31. This, as explained above, differs from the traditional postforming, where the edge portion is machined and the surface layer is glued to the part of the core that has the same lower tight mb.

On figa shows an alternative method of forming a portion 20 of the edges in the flooring of the BOB. The flooring board 1 is made with an edge groove 19 located under the surface layer 31. The upper part of the edge groove 19 consists of a surface layer 31 and part of the core 30. This upper part of the edge groove 19 is bent to the lower part of the edge groove 19, and both parts are pressed and glued together together. Fig. 6b shows that such a method can be used to form a portion of the edge of the flooring panel, which is then machined to obtain a flooring board. Both of these methods are more complex than forming by pressing, since they require glue and a separate machining operation. This method can be partially combined with compression and the core can be pressed during gluing.

Figure 7 shows the profile of the joint 4 with extruded sections 20, 20 'of the edges of the present invention.

FIG. 8 shows a floorboard with portions 20 on opposite edges that are curved and where the outer adjacent portions of the edge surfaces 50 are substantially parallel to the horizontal plane HP.

Fig. 9 shows a floorboard where the surface of the edge portion 20 at the long edges 4a, 4b contains a material different from the material of the edge surface of the portion 20 ′ of one of the short edges 5a. Long edges can preferably be formed by the method shown in figa. In this embodiment, one of the short edges 5a has a portion 20 ′ in the form of a decorative groove substantially parallel to the horizontal plane HP, as shown in FIG. 3a. The edge surface on long edges is a laminate made of melamine-impregnated paper, and on one short edge, the surface is fiberboard, which can be dyed. Various combinations can be used to improve the appearance and reduce production costs, for example laminate / film, laminate / print, film / print, laminate / impregnated laminate / film, etc. Of course, long and short edges can be formed according to the first aspect of the present invention.

The present invention is particularly suitable for the production of laminate flooring, which looks like solid floorboards with a width of 5-10 cm and where the pressed sections of the edges are formed only on the long sides. Such flooring boards can easily be produced with an arbitrary length, because it is possible to produce long flooring panels formed by pressing, which are then machined and cut into boards of different lengths. Of course, it is also possible to form a machined area on one short edge. Visible wood fibers can be painted. The present invention is also very suitable for the production of laminate panels with a width of 10-12 cm or 12-15 cm, where it is difficult to use traditional methods.

The flooring, consisting of such narrow boards, will have many curved sections of 20 edges, and to obtain competitive costs for the production of flooring, which is cheaper than solid wood flooring, you need to use only very cost-effective methods, such as molding.

Compression molding is very effective and fully meets the speed requirements of modern production lines.

The method of pressing a core with a surface layer of a laminated flooring element, flooring panel or flooring board or similar building element in the form of a panel of the present invention can be used to form embossed areas on other parts, and not just edges.

Claims (32)

1. A flooring board with a locking system comprising a core (30) based on wood fiber and a surface layer (31) located on the upper side of the core, while the upper flat parts of the surface layer form the flooring surface (33) and the horizontal plane (HP), and a plane perpendicular to the horizontal plane and passing at the outer edge (51) of the surface layer (31) forms a vertical plane (VP), while the floorboard has an edge portion (20) with a surface (50) located below the horizontal plane, at ohm, the edge surface of the vertical plane is located at a distance from the horizontal plane, which forms the depth (ED) of the edge and exceeds the thickness (ST) of the surface layer, characterized in that the flooring surface and the edge surface are made as a whole from one material, while part of the core on the edge portion under the edge surface adjacent to the vertical plane and located at a vertical distance (SD) from the edge surface, has a density (D) higher than the density of the core part, is located under the surface of the flooring adjacent to the edge area and at the same vertical distance (SD) from the floor surface.
2. Board according to claim 1, characterized in that the edge surface (50) is made curved.
3. Board according to claim 2, characterized in that the edge surface (50) is a convex curve.
4. The board according to claim 3, characterized in that the tangent TL to the convex curve forms an angle with a horizontal plane (HP) in excess of 10 °.
5. The board according to claim 3, characterized in that the tangent TL to the convex curve forms an angle with a horizontal plane (HP) in excess of 15 °.
6. The board according to claim 3, characterized in that the tangent TL to the convex curve forms an angle with a horizontal plane (HP) in excess of 20 °.
7. Board according to any one of claims 1 to 6, characterized in that the core (30) is made of high density fiberboard.
8. The board according to claim 7, characterized in that the board has a width of less than 15 cm
9. The board according to claim 7, characterized in that the board has a width of less than 12 cm
10. Board according to claim 4, characterized in that the surface layer (31) consists of at least one layer of paper impregnated with a thermosetting resin, deposited directly on the board and pressed with it by pressure and under the influence of heat.
11. Board according to claim 10, characterized in that the surface layer (31) consists of at least one layer of paper impregnated with a thermosetting resin, applied directly to the board and pressed with it by pressure and under the influence of heat without the use of glue.
12. Board according to claim 4, characterized in that the surface layer (31) is wood veneer.
13. Board according to claim 1, characterized in that the depth (ED) of the edge is at least 2 times the thickness of the surface layer (ST).
14. Board according to claim 1, characterized in that the depth (ED) of the edge is at least 3 times the thickness of the surface layer (ST).
15. Board according to claim 1, characterized in that it contains a mechanical locking system (9, 10, 8, 12), configured to connect the board (1) with a previously installed board (1 ') by inserting it at an angle and / or snap into locked position.
16. A method of manufacturing a flooring board with a locking system, a wood fiber core (30) and a surface layer (31) located on the upper side of the core, the outer flat parts of the surface layer (31) forming the flooring surface (33) and a horizontal plane (HP ), while the flooring board has an edge portion (20) with a surface (50) located below the horizontal plane, characterized in that it comprises the steps of: applying a surface layer (31) to the core to form the flooring element (3); cut the flooring element on the flooring panel (2); apply pressure to the surface of the edge portion of the flooring panel (20) and press the core under the surface layer, and constantly bend the surface layer to the back side.
17. The method according to clause 16, wherein the surface layer (31) contains sheets of paper impregnated with a thermosetting resin.
18. The method according to clause 16, wherein the surface layer (31) is wood veneer.
19. The method according to any one of paragraphs.16-18, characterized in that the core is made of high density fiberboard.
20. The method according to clause 16, characterized in that it comprises the step of pressing the edge portion (20) when exposed to heat of more than 100 ° C.
21. The method according to clause 16, characterized in that it contains a stage at which the edge portion (20) is pressed when exposed to heat of more than 160 ° C.
22. The method according to claim 20 or 21, characterized in that it comprises the stage of pressing and heating the edge portion (20) with an infrared heating device.
23. The method according to clause 16, characterized in that it comprises the step of forming a mechanical locking system (9, 10, 6, 8) on the edge of the panel (2) of the floor after applying pressure.
24. The method according to clause 16, characterized in that it comprises the step of forming an edge groove (16) on the edge of the floor panel (2) before applying pressure.
25. The method according to clause 16, characterized in that it comprises the step of applying pressure by moving the pressure shoe or pressure wheel relative to the floor panel (2).
26. A method of manufacturing a building panel (2) with a wood fiber core (30) and a surface layer (31) located on the upper side of the core (30), the flat parts of the surface layer forming the floor surface (33) and the horizontal plane (HP) wherein the building panel has an edge portion (20) with a surface (50) below the horizontal plane, characterized in that it comprises the steps of: applying a surface layer (31) to the core (30) to form the building element (3) cut construction the th element (3) on the building panel (2); apply pressure to the surface of the edge portion (20) of the building panel (2), press the core (30) under the surface layer (31), and bend the surface layer (31) constantly to the back of the core (30).
27. The method according to p, characterized in that the surface layer contains sheets of paper impregnated with a thermosetting resin.
28. The method according to p. 26 or 27, characterized in that the method comprises the step of applying pressure by moving the pressure shoe or pressure wheel relative to the floor panel (2).
29. A rectangular flooring board containing pairs of opposing long (4a, 4b) and short (5a, 5b) edges, a mechanical locking system on at least one pair of edges, a wood fiber core (30) and a surface layer (31 ) a laminate located on the upper side of the core, while the outer flat parts of the surface layer form the flooring surface (33) and the horizontal plane (HP), while the flooring board contains sections on the long edges and at least on one of the short edges ( 20, 20 ') with surfaces (50), cat rye located under the horizontal plane characterized in that the surface (20) on the long edge (4a) comprises a material characterized by a surface (20 ') short edge (5a).
30. Board according to clause 29, wherein the surface of the flooring and the surface of the edge on the long edges are made in one piece from one material.
31. The board according to item 30, wherein the surface of one short edge contains wood fibers of high density.
32. The board according to p, characterized in that the wood fibers of high density are dyed or impregnated.
RU2007134443/03A 2005-02-15 2006-02-15 Construction panel with compressed edges RU2358076C1 (en)

Priority Applications (2)

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EP05003173A EP1691005B1 (en) 2005-02-15 2005-02-15 Method to make a floorboard with compressed edges
EP05003173.1 2005-02-15

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NZ556542A (en) 2010-11-26
JP2008530409A (en) 2008-08-07
KR101274135B1 (en) 2013-06-13
RS51078B (en) 2010-10-31
SI1691005T1 (en) 2010-01-29
EP1691005B1 (en) 2009-08-19
WO2006088417A2 (en) 2006-08-24
WO2006088417A3 (en) 2006-11-09
EP1915492A4 (en) 2012-09-05
AT440190T (en) 2009-09-15
CA2598340C (en) 2014-07-15
EP1691005A1 (en) 2006-08-16
DE602005016069D1 (en) 2009-10-01
KR20070107125A (en) 2007-11-06
BRPI0606347A2 (en) 2009-06-16
AU2006214827B2 (en) 2011-07-14
CY1109628T1 (en) 2014-08-13
NO339541B1 (en) 2016-12-27
PT1691005E (en) 2009-11-04
PL1915492T3 (en) 2018-01-31
CN101120145A (en) 2008-02-06
JP4926983B2 (en) 2012-05-09
CN101503907A (en) 2009-08-12
CA2598340A1 (en) 2006-08-24
DK1691005T3 (en) 2009-11-30
AU2006214827A1 (en) 2006-08-24
HRP20090585T1 (en) 2009-12-31
CN101503907B (en) 2012-06-13
PL1691005T3 (en) 2010-01-29
ES2330753T3 (en) 2009-12-15
EP1915492B1 (en) 2017-08-16
ZA200706082B (en) 2009-02-25
CN100485150C (en) 2009-05-06
IL184579D0 (en) 2007-10-31
NO20073577L (en) 2007-11-07
UA91212C2 (en) 2010-07-12
EP1915492A2 (en) 2008-04-30

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