Alternating Wood and Polymer Blocks in Floor Panel Core
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Solution Overview
Problem
Existing parquet floor panels have limited cost reduction potential due to the use of high-quality wood materials, which increases production costs and weight, making them expensive and difficult to transport and install.
Innovation Solution
Incorporating second material blocks, such as expanded polymer materials or engineered wood products, with lower strength and density than wood blocks, alternately with wood blocks in the core layer to reduce material costs and weight, while maintaining structural integrity and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-quality wood blocks are used in the core layer, then the structural integrity and aesthetic appeal of the floor panel are maintained, but the production cost and weight increase
Solution Approach 1:
The patent applies composite materials by combining wood blocks with second material blocks (such as polymer blocks or engineered wood products) in the core layer. This composite construction maintains the structural integrity and aesthetic appeal of traditional wood parquet while reducing the overall weight and production cost, as the second material has lower density and cost than solid wood blocks.
Solution Approach 2:
The patent implements local quality by creating alternating portions of wood blocks and second material blocks along the principal direction of the floor panel. This localized substitution allows the floor panel to maintain wood-like appearance and sufficient structural performance in critical areas while reducing weight and cost in less critical areas, achieving a balanced compromise.
2Strength
If high-quality wood blocks are used in the core layer, then the structural integrity of the floor panel is maintained, but the production cost increases
Solution Approach 1:
The patent uses composite materials by alternating wood blocks with second material blocks (polymer blocks or engineered wood products) in the core layer. This approach maintains the structural integrity and aesthetic appearance of traditional wood parquet while significantly reducing production costs, as the second material is less expensive than solid wood blocks.
Solution Approach 2:
The patent applies local quality by substituting wood blocks with second material blocks in alternating portions along the principal direction of the floor panel. This localized substitution maintains sufficient structural performance and visual appeal while reducing material costs, achieving a cost-effective solution that does not compromise overall quality.
3Weight of moving object
If second material blocks are incorporated in the core layer, then the weight and cost are reduced, but the tensile strength may be compromised
Solution Approach 1:
The patent employs composite materials by combining wood blocks with second material blocks (such as polymer foam blocks or engineered wood products) in alternating portions of the core layer. This composite structure reduces weight and cost while maintaining sufficient tensile strength through the synergistic combination of materials, where wood blocks provide strength and second material blocks provide lightweight filling.
Solution Approach 2:
The patent implements local quality by strategically placing second material blocks in alternating portions along the principal direction of the floor panel, rather than uniformly replacing all wood blocks. This localized substitution maintains tensile strength in critical areas where wood blocks are positioned while reducing weight and cost in less critical areas.
Data Source
Figure 1~2
Figure 3~5
Figure 6a~6c
AI summary
The present document discloses a floor panel comprising a decorative layer (13), and a core layer (10, 11) arranged below the decorative layer (13) when the floor panel is substantially horizontally oriented. The core layer comprises a plurality of wood blocks (10) arranged with their respective principal fiber directions substantially parallel with a plane (So) defined by a major surface of the floor panel and substantially perpendicular to a principal direction (L) of the floor panel. The core layer (10, 11) comprises a plurality of second material blocks (11), made from a different material than said wood blocks (10). Along the principal direction (L) of the floor panel, the core layer presents alternating portions formed of said wood blocks (10) and of said second material blocks (11).