Method and device for floor panels production

FIELD: equipment for laminated structure compaction, particularly to produce floor panels.

SUBSTANCE: compaction device comprises two heated compaction plates, gripping transporting means, means for moving heated plates to laminated structure and compacting thereof. Gripping transporting means is adapter to clamp laminated structure and to move thereof to space between compaction device plates. Means for moving heated plates are controlled in such a way that heated plates simultaneously reach laminated structure and simultaneously move away from it. Plate area, which transfers pressure to laminated structure is at least 1 m3. Temperature and pressure is applied to laminated structure in the device from both sides thereof, which results in gluing structure layers together. Heating for glue melting is performed simultaneously from both structure sides. Laminated structure is adapted to produce floor panels having width of at least 300 mm and length of at least 800 mm and thickness not more than 15 mm. Grooves and ridges are cut in side panel edges. Panels have additional locking means to connect panels without glue.

EFFECT: prevention of shift during transferring heat.

12 cl, 2 dwg

 

The technical field to which the invention relates.

The present invention relates to a device and method for pressing a layered system for the manufacture of panels, and the panels made in this way.

The level of technology

From European patent document No. EP 0906994 A1 famous panel in the form of an elongated thin plate which can be connected to other panels on the side, for example, by connecting the tongue and groove. United thus the panels are used in particular as a floor covering.

In accordance with the prior art panel manufactured by the method of pressing with a short cycle, namely in the following way. On resin-impregnated plenkoobrazovatel layer, which is called “wrong paper”, impose supporting plate. On it are placed the other resin-impregnated decorative plenkoobrazovatel layer. This layer is known as the “decorative paper”. The following plenkoobrazovatel the layer containing the oxide and the resin applied on the decorative layer. This layer is known as the “floor”. Due to the coating is achieved, the desired rigidity of the upper surface of the panel. Thus formed layered system capture for edges by means of a gripping means and serves to press. The press consists essentially of two spaced pairs is lelno each other plates, heated to a temperature of about 200°C. a Layered system is placed on the bottom plate of the press. Then lower the top plate so that the layered system is pressed. Resin melt through transmitted from the heat plates. Next, the top plate raise. The gripper with vacuum suction cups fail to layered system and lowered it. Vacuum suction cups are pressed against the layered system and stick to it. Next, the layered system is lifted and transferred from the press. This layered system, using these devices is cut into panels, which typically have a length of from about 1200 to 1300 mm, a thickness of from 5 to 12 mm and a width of about 200 mm In conclusion, the panels typically perform tongue-and-grooves and ridges, usually by way of milling. Using a sheet of grooves and ridges of the panel are connected. Further, they form a floor or wall sheathing.

Interconnected panels collect, for example, in the floor, known as laminated or laminated flooring.

The drawback of such a floor coverings is a relatively large number of joints or connecting seams of the panels. On the one hand, such joints are undesirable for aesthetic reasons. On the other hand, remain in or with the passage of time and there are gaps or cracks, in which can penetrate moisture or contamination. Moisture damage to the panel. Pollution spoil the appearance and unhygienic.

The number of connecting joints can be significantly reduced if the panel had a width substantially greater than 200 mm But at present, the production conditions do not allow to produce a wide panel of required quality.

The problem in manufacturing is the transfer of heat with a time shift. As soon as the specified layered system placed on the bottom plate of the press, it is passed to heat from below, causing the melting of the resin on the bottom side. In this period of time the resin on the top side remains solid. Further, after the operation of pressing the heat transfer from the top stops, but layered system remains for some time on the bottom plate. Accordingly, the resin in the upper region of the panel hardens much faster. All these misalignments cause minor curvature of the layered system, which remain after removal from the press.

These curvatures are especially noticeable in floor coverings for wide panels. In order to avoid this undesirable optical effect, the panels are usually made narrow.

The invention

The problem to which the present invention is directed, is to reduce the numbers the connecting seams in the floor covering, the assembled panels.

In accordance with the invention the solution of this problem is achieved by using a pressing device for pressing a layered system for the manufacture of panels intended for floors containing two heated pressing plates; transport-gripping means which has a thickness of from 5 to 12 mm layered system for manufacturing floor panels can be captured and transported to the position between the plates of the pressing device; and means for moving intended for movement of the heated plates to the layered system and pressing. The position of the heated plates relative to the position of the transport gripper means is selected so that the transport-gripping means are located next to the pressure plates, i.e. can't get between the pressure plates.

Distinctive features of the device is that management move is designed so that both the heated plate simultaneously reach the layered system and also simultaneously removed from the layered system after the operation of pressing a sufficient duration. The area of the plate, through which is passed the pressure to be pressing the layered system is at least 1 square meter.

In the device p is the invention heat is supplied at the same time. Stages of melting or curing of the resin divided by time. Due to this eliminated the formation of the corresponding curvatures. This allows the manufacture of panels are very good quality and significantly greater width in comparison with the known panels.

The problem of curvature refers exclusively to the thin panels, i.e. panels with thickness up to 12 mm, the thicker the panel, the lower bent surface during manufacture, when the flow of heat to one side is for a few seconds before to the other side. The panel is thinner than 5 mm is too fragile, so it is advisable to set the lower limit of the thickness value of at least 5 mm

The pressure plate is heated using the heating means to the desired operating temperature. Preferably, the plates were made with the possibility of heating to a temperature of from 150 to 250°and the device is provided with control means by which the plate can be heated to different preset values of temperature.

Of course, for the manufacture of a wide panels is not indispensable that the device according to the invention had all the described design features. It is essential that regular two-way supply of heat was produced without time shift, even for a few seconds. This includes the AC is to the beginning of the heat, and his end. This avoids the time shift of the melting process or curing resins.

In accordance with the method of manufacture of the panels, allowing to solve the problem, provided is subject to melting adhesive layered system is subjected to the pressure device, the pressure and temperature of the two sides in such a way that due to this impact the layered system is glued, with double-sided thermal effects for melting adhesive carried out simultaneously.

Distinctive features of the method is that of a layered system made floor panel of a width of at least 300 mm, a width of at least 800 mm and a thickness of not more than 15 mm On the lateral edges of the panels perform milled tongue-and-grooves and ridges, as well as perform additional locking means enabling the panels together without glue.

Temperature, the effects of which during the operation of pressing is exposed to the upper side of the layered system may differ from the temperature effects on the lower side. The purpose of this action is to obtain a good result when used various resins with different melting point. Specific working temperature impact below or above should ootvetstvovali the melting point of the resin. Usually, to get good results requires a temperature difference of at least 10%. In the preferred embodiment, when the compressing panel is subjected to a temperature on the upper side at a temperature different from the temperature effects on the lower side, and the temperature difference is at least 10°C. this significantly reduces the distortion caused by the production process. The temperature on the upper side may be different from the temperature on the lower side by the value, for example equal to 20°C. the Optimal temperature values in some cases can be determined by experiment.

Be pressing layered system preferably contains supporting plate.

The invention relates also to the panel produced by the proposed method. The panel according to the invention made according to the width of at least 300 mm, the length of at least 800 mm and not thicker than 15 mm, Even panels of a width > 600 mm have the desired quality. However, during normal length panels up to 2000 mm to work with panels of such a large width is already quite difficult. Therefore, the widths greater than 600 mm is already impractical in view of the average consumer. The optimum dimensions are width from 380 to 400 mm, which is twice the width of normal panels

When the panel is placed on the floor, the floor is transferred to the floor formed by the panels. Such unevenness may appear from grains of sand or small stones, etc. between the floor and laid on it by the panels. In such cases, the connections or joints between the panels are at high stretching forces. The wider the bar, the stronger the effect, as the lever arm action efforts. Therefore, the panels of a width exceeding 300 mm, manufactured in accordance with the invention, should be interconnected in an especially reliable manner, to withstand the specified tensile strength.

To this end, the panel according to the invention provided with grooves and ridges to connect two panels double joint in the tongue and groove. This dual connection in the tongue and groove, when the edges of the panels are provided with spaced one above the other groove and a crest, is known from European patent document No. EP 0906994 A1, but not in combination with panels of a width > 300 mm

The panel also provides additional locking means for the panels together without glue. This additional locking means for glueless connection is known from European patent document EP 0877130 A2, EP 0855482 B1, U.S. patent No. 5295341 or No. 4426820. However, experience has shown that in modern echnique production is impossible to achieve such a precision manufacturing, so, for example, to avoid creating a triangular gap (in the sense of decisions of the European patent document EP 0855482 B1). Only the method of manufacturing in accordance with the invention, which eliminates the distortion that gives the possibility of such precision manufacturing that two panels can be connected to each other reliably, accurately and without backlash.

In a preferred embodiment, the panel tongue and groove are located one above the other, and below the groove or ridge is made larger than the upstream ridge or groove. The grooves and ridges is preferably tapered in cross-section, and above, respectively, the tongue and groove can be made wedge-shaped in form.

As an additional locking means may be provided at least one groove on the bottom side of the panel and at least one projection which enters into the groove on the bottom side in the assembled state of the two panels.

List of figures

The embodiments of the present invention will be described in more detail below with reference to the accompanying drawings, on which:

1 schematically depicts a device for pressing a layered system for manufacturing floor panels,

figure 2 depicts two panels interconnected lateral sides

Information on twardawa the possibility of carrying out the invention

Figure 1 shows the device for pressing a layered system for manufacturing floor panels. Layered system 1 includes a supporting plate and located on the top and bottom films, strips and similar layers impregnated with resin. Using transport-gripping means 2 layered system 1 serves in the direction of the arrow 3 between the two plates 4 of the pressing device. In this position, the transport-gripping means 2 is located laterally next to the pressing plates 4 so that do not fall between the plates 4 in the pressing process. Plate 4 is heated to a temperature of about 200°using non-heating elements. The exact value of the temperature set in accordance with the melting point to be melted resin.

When layered system 1 is located between the plates 4, moved them in the direction of the arrows 5, i.e. to the layered system 1. The movement of the plates 4 are produced in such a way that they simultaneously come into contact with a layered system and is pressed. As a result of this layered system 1 is subjected to the simultaneous influence of temperature and pressure on the top and bottom. Resin on both sides of the carrier sheet is melted at the same time, and not shift for a few seconds, as it was produced in the known methods.

After a sufficient pressing oishii system 1 plate 4 at the same time removed from the layered system in directions opposite the arrows 5. At the same time stops the effects of temperature and simultaneously curing the resin, i.e. adhesives.

When applying the method and the means that are illustrated by figure 1, is achieved especially smooth molded layered system 1, which is the usual way is cut into panels of a width of at least 300 mm and a length of at least 800 mm Tongue-and-grooves and ridges or similar elements for connection of the panels in the floor perform milling at the final stage.

Figure 2 shows two panels 6, connected to each other by lateral edges to form between them a connecting seam 7. In the General case, this connection is not shown here sportowego tongue and groove, which perform milling on the side edges of the panels. Preferably the side edges has a dual connection in the pile. One ridge of each panel are inserted into the corresponding groove of the adjacent panel on glue. After drying, glue the two panels are connected.

If as a result of irregularities resulting force from below by the arrow 8, the connecting seam 7 is passed to a high mechanical load. The load depends on the lever arm of the force, which is greater, the wider the panel. Due to the double-connection-groove is created is particularly stable and durable connection.

As an additional locking means for the connection of two panels without the adhesive is at least one groove on the bottom side of one panel and at least one projection to another panel. The projections do so that when assembling the two panels they are in the groove on the bottom side of the respective adjacent panel.

1. Pressing device for pressing a layered system for the manufacture of panels intended for floors containing two heated pressing plate (4), transport and gripping means (2), by means of which having a thickness of 5 to 12 mm layered system (1) for the manufacture of floor panels can be captured and transported to the position between the plates (4) of the pressing device, means for moving intended for movement of the heated plates (4) to the layered system (1) and pressing, while the position of the heated plates relative to the position of the transport gripper means is selected so that the transport-gripping means (2) located next to the pressure plates (4), characterized in that the control means move designed so that both of the heated plate (4) simultaneously reach the layered system (1) and also at the same time removed from the layered system and the frontal plate (4)through which passes the pressure to be pressed with OATUU system, is at least 1 m2.

2. The device according to claim 1, characterized in that the heated plate (4) made with the possibility of heating by using a heating means to a temperature of 150 to 250°C.

3. The device according to claim 1 or 2, characterized in that it is provided by the management tool, with which the plate (4) can be heated to different pre-defined temperature values.

4. A method of manufacturing a panel, comprising stages: supplied prone to melting adhesive layered system is subjected to the pressure device, the pressure and temperature of the two sides in such a way that due to this impact the layered system is glued, and double-sided thermal effects for melting adhesive carried out simultaneously, characterized in that the layered system made floor panel of a width of at least 300 mm, a width of at least 800 mm and not thicker than 15 mm, the lateral edges of which perform milled tongue-and-grooves and ridges, perform additional locking means enabling the connection panel without adhesive.

5. The method according to claim 4, characterized in that during pressing of the panel is subjected to a temperature on the upper side at a temperature different from the temperature effects on the lower side, the rich, the temperature difference is at least 10° C.

6. The method according to claim 4 or 5, characterized in that subject pressing a layered system contains supporting plate.

7. Panel, characterized in that it is manufactured by the method according to any of claims 4 to 6, and the panel is made across the width of at least 300 mm, the length of at least 800 mm and thickness less than 15 mm; the side edges of the panels are provided with a groove and a crest, and in the panel to provide additional locking means by which the panels can be joined without glue.

8. The panel according to claim 7, characterized in that the tongue and groove are located one above the other.

9. Panel of claim 8, wherein the lower groove or ridge is made larger in size than above the ridge or groove.

10. Panel according to any one of claims 7 to 9, characterized in that the grooves and ridges are provided with a tapered cross-section.

11. Panel of claim 8 or 9, characterized in that located respectively above the tongue and groove are made wedge-shaped in form.

12. Panel according to any one of claims 7 to 9, characterized in that as an additional locking means is provided at least one groove on the bottom side of the panel and at least one projection which enters into the groove on the bottom side in the assembled state of the two panels.



 

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5 cl, 1 dwg, 2 ex

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