Coated Panel Coupling Structure for Local Expansion Relief
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Solution Overview
Problem
Existing coated panels suffer from issues such as moisture sensitivity, sound of walking, and dimensional changes due to humidity or temperature variations, leading to local expansion effects like 'hot spots' and 'peaking' in floor coverings.
Innovation Solution
A coated panel design with a substrate comprising a thermoplastic layer and mechanical coupling means allowing displacement along edges, featuring compressible portions and horizontally acting locking surfaces to compensate for local expansion, minimizing deformation and peaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If panels with rigid substrate (HDF, PVC) are used, then structural stability is improved, but dimensional change resistance deteriorates due to humidity or temperature variations
Solution Approach 1:
The substrate uses a multi-layer plastic structure with different plasticizer contents to create varying degrees of compressibility. The first layer has higher plasticizer content (more compressible) while the second layer has lower plasticizer content (less compressible), allowing the substrate to adapt its dimensional stability to environmental conditions
Solution Approach 2:
The substrate comprises a composite multi-layer plastic structure where layers with different compositions (different plasticizer contents) are combined. This composite structure provides both structural stability and dimensional change resistance by allowing controlled compression in specific layers
2Stability of the object's composition
If horizontal locking surfaces are formed on rigid substrate, then locking stability is improved, but adaptability to local expansion deteriorates
Solution Approach 1:
The horizontal locking surfaces are formed on the first layer of the substrate which has higher plasticizer content and is therefore more compressible. This allows the locking surfaces to adapt to local expansion through compression while maintaining locking stability
Solution Approach 2:
Different layers of the substrate have different compressibility properties. The first layer is designed to be more compressible to accommodate local expansion at the locking surfaces, while the second layer provides structural support with lower compressibility
3Adaptability or versatility
If displacement along edges is allowed in coupling means, then adaptability to expansion is improved, but locking stability in horizontal direction deteriorates
Solution Approach 1:
The coupling means incorporate compression elements that can be compressed horizontally to allow panel displacement along edges while maintaining locking stability through the vertical locking mechanism and the compressible nature of the elements
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 design effectively minimizes the formation of bubbles and 'peaking' in floor coverings by allowing edge displacement and using compressible surfaces to absorb dimensional changes, ensuring a stable and uniform installation.
Implementation Method 1
this contact surface is formed mainly, and preferably exclusively, on a compressible portion of the substrate and/or the top layer
Data Source
AI summary
A coated panel with a substrate and a decorative top layer. The substrate includes an, optionally filled, plastic composite. The coated panel is provided on at least a first pair of two opposite edges with mechanical coupling means that allow two such panels to be coupled to each other on the first pair of edges in question. Locking is obtained both in a vertical direction perpendicular to the plane of the coupled panels, and in a horizontal direction perpendicular to the respective edges and in the plane of the coupled panels. The mechanical coupling means or coupling parts allow a displacement in the direction along the coupled edges.