Composite Building Panels with Perforated Veneer for Dimensional Stability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Building panels made from wooden materials deform or deflect under extreme environmental conditions, leading to visual and structural issues.

Innovation Solution

A building panel comprising a core with two fibrous bodies bonded by adhesive and a veneer facing layer with perforations, providing dimensional stability and airflow properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If wooden materials are used for building panels, then the panels resemble natural wood and provide structural support, but the panels deflect and permanently deform when exposed to extreme environmental temperatures and humidity

Engineering Contradiction:

Improvedimensional stabilityVSAvoiddeformation under environmental exposure

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining a rigid core (made from cementitious or gypsum-based materials) with a wood veneer facing layer. This composite structure provides the dimensional stability of the rigid core while maintaining the aesthetic appearance of wood through the veneer, thereby resolving the contradiction between wood-like appearance and resistance to environmental deformation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by using different materials for different functional requirements: the core provides structural stability and resistance to environmental factors, while the thin veneer layer provides the wood-like aesthetic appearance. This localized assignment of material properties allows the panel to achieve both dimensional stability and visual appeal without the drawbacks of solid wood.

Inventive Principle:

Principle #3Local quality

2Shape

If solid wood panels are used to achieve wood-like appearance, then the aesthetic requirement is met, but weight concerns arise

Engineering Contradiction:

Improvewood-like appearanceVSAvoidpanel weight

Core Design Contradiction:

ShapeVSWeight of stationary object

Solution Approach 1:

The patent uses composite materials where a lightweight rigid core is combined with a thin wood veneer facing. This composite construction achieves the wood-like appearance of solid wood panels while significantly reducing the overall weight, as the core material (cementitious or gypsum) is lighter than solid wood and the veneer layer is much thinner than traditional wood panel thickness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies the copying principle by using a thin veneer layer that replicates the appearance of solid wood without requiring the full thickness and weight of solid wood panels. The veneer copies the aesthetic qualities of wood grain and texture while the lightweight core provides structural support, achieving visual fidelity with reduced mass.

Inventive Principle:

Principle #26Copying

3Reliability

If traditional building panels are used, then structural support is provided, but airflow properties and sound absorption are limited

Engineering Contradiction:

Improvestructural supportVSAvoidsound reflection

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies porous materials by incorporating perforations in the veneer facing layer and using the rigid core as an acoustic absorber. The perforations allow airflow through the panel, and the core material absorbs sound waves, thereby reducing sound reflection while maintaining structural support. This resolves the contradiction between providing structural integrity and improving acoustic performance.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent applies segmentation by dividing the panel into functional layers: a rigid core for structural support and acoustic absorption, and a perforated veneer facing for airflow and aesthetic purposes. This segmentation allows each layer to optimize its specific function, with the core handling structural and acoustic requirements and the veneer handling airflow and appearance requirements.

Inventive Principle:

Principle #1Segmentation

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 maintains dimensional stability and acoustic performance without increasing weight, offering superior sound absorption and reduced sound reflection.

Implementation Method 1

an adhesive is present in the interface

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

the veneer facing layer comprising a plurality of perforations

Methodology Applied

Scientific EffectAirflow through porous structure: Porosity

Implementation Method 3

superior sound absorption and reduced sound reflection

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Data Source

PatentUS12448774B2Dimensionally stable building panel

Publication Date: 2025.10.21 ARMSTRONG WORLD IND INC

AI summary

Described herein is a building panel and related building systems, the building panel having a first major surface opposite a second major surface, the building panel comprising a core comprising a first body comprising a first fibrous material; and a second body comprising a second fibrous material, a veneer facing layer coupled to the core, the veneer facing layer comprising a plurality of perforations.