Cavity-Core Composite Panel for Acoustic and Dimensional Stability
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Solution Overview
Problem
Existing rigid flooring materials, such as SPC, offer superior dimensional stability and impact resistance but suffer from unsatisfactory acoustic performance, while flexible alternatives like WPC provide better sound absorption but lack stability.
Innovation Solution
A panel design featuring a multilayer core with a lower core layer containing impressed cavities and a higher Vicat softening temperature than the upper core layer, enhancing acoustic performance without compromising rigidity or stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solid core SPC is used to increase rigidity and dimensional stability, then dimensional stability and impact resistance are improved, but acoustic performance deteriorates
Solution Approach 1:
The patent applies composite materials by combining an upper SPC layer (providing dimensional stability) with a lower WPC layer (providing acoustic performance). This creates a hybrid core structure where each material contributes its advantageous properties, resolving the contradiction between rigidity and sound absorption.
Solution Approach 2:
The core is segmented into multiple layers with different material compositions - an upper layer and a lower layer. This segmentation allows each layer to be optimized for its specific function: the upper layer for structural stability and the lower layer for acoustic performance, thereby resolving the technical contradiction.
2Object-affected harmful factors
If WPC is used to improve acoustic performance, then sound absorption is improved, but dimensional stability deteriorates
Solution Approach 1:
The patent uses composite materials to combine WPC (for acoustic performance) with SPC (for dimensional stability). The lower layer uses WPC to absorb sound while the upper layer uses SPC to maintain structural rigidity, resolving the contradiction between these two properties.
Solution Approach 2:
The core is divided into segmented layers where the lower layer is dedicated to acoustic performance using WPC, while the upper layer maintains dimensional stability using SPC. This functional segmentation resolves the contradiction by assigning each material to its optimal role.
3Object-affected harmful factors
If additional acoustic layers are added to improve sound absorption, then acoustic performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the structural core and acoustic damping functions into a single integrated core layer. The lower WPC layer serves dual purposes as both structural support and acoustic dampening layer, eliminating the need for separate acoustic layers and reducing overall product complexity.
Solution Approach 2:
The lower WPC layer is designed to perform multiple functions simultaneously: providing structural support, reducing weight, and delivering acoustic dampening. This multi-functionality eliminates the need for additional dedicated acoustic layers, thereby reducing device complexity while maintaining acoustic performance.
4Strength
If solid core SPC is used to increase rigidity, then indentation resistance is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by using a lower density WPC layer instead of solid SPC throughout the entire core. This reduces overall weight while the upper SPC layer maintains indentation resistance, resolving the contradiction between strength and weight.
Solution Approach 2:
The patent applies local quality by using different material densities in different layers - the upper layer uses higher density SPC for indentation resistance where needed, while the lower layer uses lower density WPC for weight reduction. This localized material selection resolves the contradiction between strength and weight.
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
The panel achieves improved sound absorption and reduced weight by diffusing sound waves through the cavities, eliminating the need for additional sound dampening layers and maintaining structural integrity.
Implementation Method 1
at least part of the bottom surface of the lower core layer is provided with a plurality of impressed cavities... improved sound absorption... diffusing sound waves through the cavities
Implementation Method 2
the Vicat softening temperature of the upper core layer is at least 15 degrees Celsius higher than the Vicat softening temperature of the lower core layer... maintaining structural integrity
Data Source
Figure 1a~1e
Figure 2a~2d
Figure 3a~3b
AI summary
The invention relates to a panel, such as a floor panel, a wall panel or a ceiling panel, in particular a decorative panel and to a method for producing such panel. The panel according to the present invention comprises a core layer comprising a first composite material and a second composite material which have different material characteristics. The panel is further provided with a plurality of cavities.