Different kinds of boards and other flat elements which are joined to each other by means of tongue and groove are well known. Tongue and groove are nowadays normally made by milling which is a rational method. It is however difficult to achieve complex cross-sections with undercuts with traditional milling, especially in narrow grooves. It is known to achieve undercuts to some degree by utilising more than one milling tool with different rotation axis. The problem with this method is however that it is very difficult to obtain desirable tolerances due to vibrations and flexing in the machine since there must be some distance between the different milling tools. The cross-section possible to be manufactured by this method is also limited since the milling tool will have to rotate through the opening of for example, a groove. It is desirable to achieve a process where the tolerance play is good, undercuts with sharper angles are possible and where dust and particles from the milling does not obstruct the process.
It has, according to the process of the present invention, been made possible to achieve profiles such as tongue and groove on boards, with better tolerances, undercuts with sharper angles and without having dust and particles from the milling process obstructing the process.
Accordingly, the invention relates to a process for the manufacturing of longitudinal profiles selected from tongue and/or groove on boards wherein the process includes the steps;
The milling tool is adjustably fixed in a conveying machine, which machine feeds the boards past the milling tool during the milling operation. The broaching tool is preferably adjustably fixed in the same conveying machine, which machine feeds the board past the broaching tool. The process is most suitably used for machining tongue and groove on thin boards such as floor boards. The tongue and groove may, through the process, be provided with a functionality which allows them to snap join. Accordingly, the moulding of the profiles is initiated by milling a substantial part of the material to be removed with a traditional milling tool. The final shape of the profiles are then achieved by broaching. The undercuts are also achieved in the broaching stage of the process.
If materials like fibre board or particle board are used it is known that burrs often occur which will obstruct the functionality in the tighter parts of a snap joint. This can be avoided by adding the step coating of the milled profile section before the broaching stage where the fine moulding takes place. The coating suitably comprises a substance selected from the group; wax, oil a polymeric material being exemplified by a thermoplastic polyolefin and a lacquer being exemplified by a UV-curing lacquer.
The broaching tool preferably comprises broaching edges, a broaching body and a broaching clamp. The broaching body is suitably provided with internal cooling channels for a cooling media, the cooling media being selected from the group consisting of a gas and a liquid. The broaching body is suitably also provided with a temperature sensor used for guiding the cooling. The temperature sensor is either an infrared sensor directed towards one or more broaching edges or a conductive sensor attached to the broaching body. The broaching tool is suitably provided with at least one nozzle for blowing air on the broaching edges. The air blown on the broaching edges may serve two purposes the first one being to remove dust and particles from the cutting edges the second one being to cool the broaching tool. It is possible to use the blown air as either a complement to, or a replacement for the internal cooling. The broaching tool is suitably also provided with an air and dust evacuation duct which evacuates dust and particles from the broaching edges. The air blown on the edges may suitably also pulsate for better cleaning of the edges.
The front edge portions of the broaching edges are suitably concave in order to increase the stability during the cutting operation and at the same time ensure secure removal of the waste material so that no or very little burr is formed. The side edge portions of the broaching edges are suitably also concave in order to increase the stability during the cutting operation and at the same time ensure secure removal of the waste material so that no or very little burr is formed.
The invention is described further in connection to the enclosed drawings showing different embodiments of the invention whereby,
a-1d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a groove 2″ in an edge of a board 1 at different steps in the process according to one embodiment of the invention.
a-2d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a tongue 2′ in an edge of a board 1 at different steps in the process according to one embodiment of the invention.
a-3d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a groove 2″ in an edge of a board 1 at different steps in the process according to a second embodiment of the invention.
a-4d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a tongue 2′ in an edge of a board 1 at different steps in the process according to a second embodiment of the invention.
Accordingly
a-2d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a tongue 2′ in an edge of a board 1 at different steps in the process according to one embodiment of the invention. The drawing is simplified by enlarging certain objects in the cross-section geometry in order to enhance the understanding of the invention.
a-3d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a groove 2″ in an edge of a board 1 at different steps in the process according to a second embodiment of the invention. The drawing is simplified by enlarging certain objects in the cross-section geometry in order to enhance the understanding of the invention.
a-4d shows, in a cross-section perspective view, a longitudinal profile 2 in the form of a tongue 2′ in an edge of a board 1 at different steps in the process according to a second embodiment of the invention. The drawing is simplified by enlarging certain objects in the cross-section geometry in order to enhance the understanding of the invention.
The broaching tool 3 comprises broaching edges 31, a broaching body 32 and a broaching clamp. The broaching body 32 is provided with internal cooling channels for a cooling media. The cooling media may be gas and a liquid. A temperature sensor used for guiding the cooling broaching body 32 is advantageously also used. The manufacturing tolerances will be better if the temperature in the broaching tool 3 is maintained within a selected range. The temperature sensor may be an infrared sensor directed towards one or more broaching edges 31 or a conductive sensor attached to the broaching body 32 itself. It also possible to achieve a narrow temperature range in the broaching tool 3 by controlling the temperature of the cooling media. The broaching tool 3 may also be provided with one or more nozzles blowing air on the broaching edges 31. The air stream is adjusted so that it will cool the broaching edges 31 as well as removing dust and particles from the same. The broaching tool 3 may furthermore be provided with an air and dust evacuation duct which evacuates dust and particles from the broaching tool 3. The air blown on the broaching edges 31 suitably pulsates for improved cleaning of the broaching edges 31.
The front edge portions 31′ and the side edge 31″ portions of the broaching edges 31 are concave in order to increase the stability during the cutting operation and at the same time ensure secure removal of the waste material so that no, or very little burr is formed.
The broaching tool 3 comprises broaching edges 31, a broaching body 32 and a broaching clamp. The broaching body 32 is provided with internal cooling channels for a cooling media. The cooling media may be gas and a liquid. A temperature sensor used for guiding the cooling broaching body 32 is advantageously also used. The manufacturing tolerances will be better if the temperature in the broaching tool 3 is maintained within a selected range. The temperature sensor may be an infrared sensor directed towards one or more broaching edges 31 or a conductive sensor attached to the broaching body 32 itself. It also possible to achieve a narrow temperature range in the broaching tool 3 by controlling the temperature of the cooling media. The broaching tool 3 may also be provided with one or more nozzles blowing air on the broaching edges 31. The air stream is adjusted so that it will cool the broaching edges 31 as well as removing dust and particles from the same. The broaching tool 3 may furthermore be provided with an air and dust evacuation duct which evacuates dust and particles from the broaching tool 3. The air blown on the broaching edges 31 suitably pulsates for improved cleaning of the broaching edges 31.
The front edge portions 31′ and the side edge 31″ portions of the broaching edges 31 are concave in order to increase the stability during the cutting operation and at the same time ensure secure removal of the waste material so that no, or very little burr is formed.
The invention is not limited by the embodiments shown since it can be varied in different ways within the scope of the invention. It is, for example, possible to mold a substantial part of the profile 2 by milling followed by fine molding by broaching without an intermediate impregnation or coating as shown in selected embodiments of the invention. It is also possible to apply impregnation or coating at later stages of the process.
Number | Date | Country | Kind |
---|---|---|---|
0100276 | Jan 2001 | SE | national |
This application is a division of U.S. application Ser. No. 10/058,968, filed Jan. 30, 2002, now U.S. Pat. No. 6,681,820, which claims priority under 35 USC §119 from Swedish Patent Application No. 0100276-5, filed Jan. 31, 2001.
Number | Name | Date | Kind |
---|---|---|---|
752694 | Lund | Feb 1904 | A |
2004193 | Cherry | Jun 1935 | A |
3535844 | Glaros | Oct 1970 | A |
3664011 | Labastrou | May 1972 | A |
3807113 | Turner | Apr 1974 | A |
4426820 | Terbrack et al. | Jan 1984 | A |
4940503 | Lindgren et al. | Jul 1990 | A |
4951391 | Seabra | Aug 1990 | A |
5165816 | Parasin | Nov 1992 | A |
5216861 | Meyerson | Jun 1993 | A |
5295341 | Kajiwara | Mar 1994 | A |
5325649 | Kajiwara | Jul 1994 | A |
5344700 | McGath et al. | Sep 1994 | A |
5502939 | Zadok et al. | Apr 1996 | A |
5630304 | Austin | May 1997 | A |
5706621 | Pervan | Jan 1998 | A |
5860267 | Pervan | Jan 1999 | A |
6006486 | Moriau et al. | Dec 1999 | A |
6023907 | Pervan | Feb 2000 | A |
6082421 | Nicol et al. | Jul 2000 | A |
6094882 | Pervan | Aug 2000 | A |
6182410 | Pervan | Feb 2001 | B1 |
6205639 | Pervan | Mar 2001 | B1 |
6357197 | Serino et al. | Mar 2002 | B1 |
6421970 | Martensson et al. | Jul 2002 | B1 |
6490836 | Moriau et al. | Dec 2002 | B1 |
Number | Date | Country |
---|---|---|
557844 | Mar 1960 | BE |
1169106 | Jun 1984 | CA |
3343601 | Jun 1985 | DE |
812671 | Apr 1959 | GB |
1430423 | Mar 1976 | GB |
2256023 | Nov 1992 | GB |
3169967 | Jul 1991 | JP |
518203 | Sep 2002 | SE |
123409 | Jun 1986 | SU |
9627721 | Sep 1996 | WO |
9747834 | Dec 1997 | WO |
2006131289 | Dec 2006 | WO |
Number | Date | Country | |
---|---|---|---|
20040250914 A1 | Dec 2004 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 10058968 | Jan 2002 | US |
Child | 10761401 | US |