Thermoplastic Building Panels With Rear Core Grooves for Weight Reduction
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Solution Overview
Problem
Existing laminated building panels, particularly those with wood fibre-based materials, face challenges in reducing weight and material content while maintaining stability and strength, especially due to the need for high-density cores and thick layers to withstand pressing and installation processes.
Innovation Solution
Incorporating core grooves on the rear side of the panels, which are formed using thermoplastic materials, to reduce material usage and weight, and utilizing the removed material for other layers or energy production, combined with a locking system that maintains panel stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-density core material is used to maintain panel strength and stability, then panel strength is improved, but panel weight increases
Solution Approach 1:
The core material is designed with a porous structure containing numerous voids or air pockets distributed throughout the core layer. This porous configuration reduces the overall density and weight of the core while maintaining structural integrity through the strategic arrangement of pores that preserve load-bearing capacity.
Solution Approach 2:
The panel employs a composite structure combining the porous core material with solid surface layers and balancing layers. This multi-layer composite design allows the porous core to provide weight reduction while the denser surface and balancing layers contribute to overall panel strength, stability, and functional performance.
2Strength
If thick layers are used to withstand pressing and installation processes, then panel strength is improved, but material content increases
Solution Approach 1:
The porous core structure achieves adequate mechanical strength and resistance to pressing and installation forces through its optimized void architecture, eliminating the need for excessive material thickness. The strategic pore distribution and size control provide structural rigidity with reduced material volume.
Solution Approach 2:
The multi-layer composite construction distributes functional requirements across different layers: the porous core provides structural framework with minimal material, while the surface layers and balancing layers contribute to overall strength, allowing each layer to be optimized for its specific function rather than requiring uniform thickness throughout.
3Stability of the object's composition
If high-density core material is used to maintain panel stability, then panel stability is improved, but production cost increases
Solution Approach 1:
The porous core material is manufactured using cost-effective processes such as extrusion or molding with foam generation techniques, allowing production of lightweight panels without requiring expensive high-density materials. The porous structure is created through economical methods like chemical foaming or physical expansion during manufacturing.
Solution Approach 2:
The composite panel structure uses the porous core as a cost-saving measure while maintaining stability through the combination with standard surface and balancing layers. This approach reduces material costs compared to using solid high-density core material throughout, while the overall panel stability is preserved through the composite action of all layers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves a significant reduction in panel weight and material content while maintaining stability and strength, allowing for cost-effective production with minimal impact on panel flatness and installation ease.
Implementation Method 1
A decorative paper 2b and a wear resistant transparent overlay paper 2a are impregnated with a thermosetting resin, such as melamine, and are applied on the upper part of a HDF core 3... The core 3 with the upper 2 and lower 4 layers is moved into a press 5 and pressed under heat and pressure such that the thermosetting resins are cured and the layers are attached to the core
Implementation Method 2
Incorporating core grooves on the rear side of the panels, which are formed using thermoplastic materials, to reduce material usage and weight
Data Source
Figure 1a~1d
Figure 2a~2d
Figure 3a~3e
AI summary
There is disclosed building panels, such as floor panels, each building panel having a surface layer and an intermediate core, wherein the intermediate core and the surface layer comprise a thermoplastic material. The building panels are provided with a vertical locking system and/or a horizontal locking system for locking a first edge of a first building panel to an adjacent second edge of a second building panel. At least two core grooves are provided in a rear side of the building panels with an opening towards the rear side, and a groove length of the core grooves is smaller than a length of the rear side.