Method for manufacturing panels

Patent metadata

Field	Value
Publication number	US-2025262705-A1
Application number	US-202519202831-A
Country	US
Kind code	A1
Filing date	May 8, 2025
Priority date	Dec 18, 2019
Publication date	Aug 21, 2025
Grant date	—

Abstract

A method for manufacturing panels such that the panels are subjected on at least one side to an operation with cutting tools. The position and/or orientation of each panel is determined prior to the operation, and the position and/or orientation of each panel is adjusted prior to the operation and/or the position of the tools is potentially adjusted, such that at least one part of each panel concerned takes a fixed orientation and position in relation to the tools.

First claim

1 . A method for machining profiled edge areas on a panel, wherein the panel comprises a substrate and a decorative top layer attached to the substrate, wherein the method comprises:
providing the panel having lower edge areas on opposite first and second sides of the panel, said decorative top layer forming the top surface of said lower edge areas; optically determining a position or an orientation of the lower edge areas; adjusting the position or orientation of the panel into a fixed orientation based on the optical determination of the position of the lowered edge areas; and then feeding the panel through a first milling machine in the fixed orientation wherein the fixed orientation is transverse to first milling tools of the milling machine such that the first milling tools remain in position relative to the fixed orientation while the panel is fed through the first milling machine as first and second profiled edge portions are formed along each of the respective lower edge areas; wherein the lowered edge areas are partially removed and at least a portion of each lowered edge area remains at a top edge of the profiled edge portion leading to the top surface of the panel; wherein said lowered edge areas are obtained by a pressing operation, which takes place between two press elements; wherein the substrate comprises thermoplastic material and fillers.

2 . The method according to claim 1 , wherein the thermoplastic material is polyvinyl chloride.

3 . The method according to claim 1 , wherein the lower edge areas have a first ascending transition zone extending in a first direction to a top surface of the panel, and a second ascending transition zone spaced apart from the first ascending transition zone and extending in a second direction different from the first direction and to a machinable portion of the panel;
optically determining said position or said orientation of the lower edge areas, by determining a position or an orientation of the second ascending transition zone; adjusting the position or orientation of the panel into said fixed orientation based on the first ascending transition zone due to the optical determination of the position of the second ascending transition zone.

4 . The method according to claim 1 , wherein the decorative top layer extends uninterruptedly from the actual top surface, over the surface of the lower edge area.

5 . The method according to claim 1 , wherein said first and second profiled edge portions define mechanical coupling parts.

6 . The method according to claim 1 , wherein said panel is a floor panel.

7 . The method according to claim 1 , wherein after feeding the panel through the first milling machine, the method comprises the step of:
feeding the panel through a second milling machine having second milling tools arranged for forming third and fourth profiled edges portions along third and fourth edges of the panel, the third and fourth edges are located transversely relative to the first and second profiled edge portions.

8 . The method according to claim 7 , wherein the second milling tools are adjusted relative to the third and fourth edges without changing the fixed orientation of the panel.

9 . The method according to claim 8 , wherein said panel is rectangular, the first and second profiled edge portions are formed along a long pair of opposite sides of the panel, and the third and fourth profiled edges are formed along a short pair of opposite sides of the panel.

10 . The method according to claim 1 , wherein during the step of feeding the panel through a first milling machine, the top surface of the panel faces downward.

11 . The method according to claim 1 , wherein said portion of each lowered edge area that remains at a top edge of the profiled edge portion leading to the top surface of the panel, forms a straight chamfer.

12 . The method according to claim 1 , wherein said portion of each lowered edge area that remains at a top edge of the profiled edge portion leading to the top surface of the panel, forms a curved chamfer.

13 . The method according to claim 1 , wherein the decorative top layer comprises a printed plastic film.

14 . The method according to claim 1 , wherein the decorative top layer comprises a print directly on the substrate.

15 . A method for machining profiled edge areas on a panel, wherein the panel comprises a substrate and a decorative top layer attached to the substrate, wherein the method comprises:
providing the panel having lower edge areas on opposite first and second sides of the panel, said decorative top layer forming the top surface of said lower edge areas; optically determining a position or an orientation of the lower edge areas; adjusting the position or orientation of the panel into a fixed orientation based on the optical determination of the position of the lowered edge areas; and then feeding the panel through a first milling machine in the fixed orientation wherein the fixed orientation is transverse to first milling tools of the milling machine such that the first milling tools remain in position relative to the fixed orientation while the panel is fed through the first milling machine as first and second profiled edge portions are formed along each of the respective lower edge areas; wherein the lowered edge areas are partially removed and at least a portion of each lowered edge area remains at a top edge of the profiled edge portion leading to the top surface of the panel; wherein said lowered edge areas are obtained by a pressing operation, which takes place between two heated press elements; wherein the substrate comprises thermoplastic material and fillers and wherein the decorative top layer comprises a printed plastic film.

16 . The method according to claim 15 , wherein after feeding the panel through the first milling machine, the method comprising the step of:
feeding the panel through a second milling machine having second milling tools arranged for forming third and fourth profiled edges portions along third and fourth edges of the panel, the third and fourth edges are located transversely relative to the first and second profiled edge portions; wherein the second milling tools are adjusted relative to the third and fourth edges without changing the fixed orientation of the panel; wherein said panel is rectangular, the first and second profiled edge portions are formed along a long pair of opposite sides of the panel, and the third and fourth profiled edges are formed along a short pair of opposite sides of the panel.

17 . The method according to claim 16 , wherein the lower edge areas have a first ascending transition zone extending in a first direction to a top surface of the panel, and a second ascending transition zone spaced apart from the first ascending transition zone and extending in a second direction different from the first direction and to a machinable portion of the panel;
optically determining said position or said orientation of the lower edge areas, by determining a position or an orientation of the second ascending transition zone; adjusting the position or orientation of the panel into said fixed orientation based on the first ascending transition zone due to the optical determination of the position of the second ascending transition zone.

18 . The method according to claim 17 , wherein during the step of feeding the panel through a first milling machine, the top surface of the panel faces downward.

19 . The method according to claim 18 , wherein the thermoplastic m

Assignees

• Unilin Bv

Inventors

• Naeyaert Christophe

Classifications

• B26D3/065

  On sheet material · CPC title

• B27M3/04 Primary

  of flooring elements, e.g. parqueting blocks (assembling wooden elements on backings of other substances B32B, {e.g. B32B21/042, E04F15/16; furniture joints F16B12/00}) · CPC title

• B27M1/08

  by multi-step processes · CPC title

• B27F1/06

  simultaneously along opposite edges of a board · CPC title

• B23Q17/249

  using image analysis, e.g. for radar, infrared or array camera images · CPC title