High-Density Cork Floor Panel Thickness Reduction
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Solution Overview
Problem
Existing cork floor panels are too thick due to the thickness of the cork layer, making them unsuitable for all installations and prone to damage during manufacturing and installation, which results in material waste.
Innovation Solution
A floor panel design with a cork layer thickness of less than 2 mm and a balancing layer thickness of 0.5 mm to 1.0 mm and density of at least 550 kg/m³, utilizing high-density cork to maintain impact sound insulation and heat insulation properties while reducing overall panel thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cork layer thickness is increased to maintain impact sound insulation and heat insulation properties, then the thermal insulation and sound insulation performance are improved, but the floor panel thickness increases making it unsuitable for all installations
Solution Approach 1:
The patent applies parameter changes by increasing the cork density from conventional values (400-600 kg/m³) to at least 550 kg/m³, and specifically 600-900 kg/m³ in preferred embodiments. This parameter change allows the cork layer to provide equivalent thermal and acoustic insulation properties at reduced thickness (0.5-2 mm), directly resolving the contradiction between insulation performance and panel thickness.
Solution Approach 2:
The patent uses composite material structure by combining high-density cork with the HDF carrier board and balancing layer. The high-density cork layer (≥550 kg/m³) works synergistically with the HDF carrier board (density 600-900 kg/m³) to achieve optimal insulation properties in a thin configuration, maintaining performance while reducing overall thickness.
2Object-affected harmful factors
If the cork layer thickness is increased to retain advantageous properties of cork floors, then the impact sound insulation and comfort properties are improved, but the floor panels become too thick and cannot be used everywhere
Solution Approach 1:
The patent changes the density parameter of cork to at least 550 kg/m³ (preferably 600-900 kg/m³), which significantly improves impact sound insulation performance per unit thickness. This allows the cork layer to be reduced to 0.5-2 mm while maintaining or enhancing sound insulation properties, resolving the contradiction between sound insulation and thickness.
Solution Approach 2:
The patent applies local quality by concentrating the insulating function in a thin, high-density cork layer (0.5-2 mm with density ≥550 kg/m³) rather than distributing it throughout a thick layer. This localized high-density approach provides equivalent sound and heat insulation in a much thinner configuration.
3Length of stationary object
If the thickness of floor panels is reduced by minimizing the thickness of backing plates, then the floor panel thickness is reduced for better adaptability, but the connecting profiles have to be of a very filigree design causing undesired damage during manufacture and installation
Solution Approach 1:
The patent changes the density parameter of the balancing layer cork to at least 550 kg/m³, which significantly enhances the mechanical strength and rigidity of the thin floor panel structure. This high-density cork provides sufficient structural support for standard connecting profiles even when the total panel thickness is reduced to 12-22 mm, eliminating the need for filigree designs and preventing manufacturing damage.
4Temperature
If cork of low density is used to compensate for thin layer thickness, then the elasticity and heat insulation are improved, but the structural stability and wear resistance are reduced
Solution Approach 1:
The patent fundamentally changes the density parameter from low density (conventional 400-600 kg/m³) to high density (at least 550 kg/m³, preferably 600-900 kg/m³). This parameter change simultaneously provides adequate heat insulation, structural stability, and wear resistance in a thin layer configuration, eliminating the need to trade off between insulation and strength.
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
This design allows for thinner, more versatile floor panels with enhanced impact sound insulation and stress equalization, while minimizing material usage and reducing the risk of damage during installation.
Implementation Method 1
cork is relatively resistant to wear and tear on the one hand and soft and elastic on the other. Due to the high elasticity, cork floors are also highly impact sound insulating
Implementation Method 2
Cork floors feel warm and comfortable because of their low thermal conductivity
Data Source
Figure 1~2
AI summary
The invention discloses a floor panel (1,1') comprising a wear layer (3, 3'), a support layer (2, 2') and a compensation layer (6, 6'), the wear layer (3, 3') comprising a cork layer (4, 4'). In order to allow the floor panel to have a thinner construction while saving on material and retaining the advantageous characteristics of the cork, according to the invention the cork layer (4, 4') has a thickness of less than 2 mm and a density of at least 550 kg/m³.