Cork-Based Laminated Panel Without Wood Layers
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Solution Overview
Problem
Existing laminated flooring panels require a structural wood layer for coupling, which increases weight and production costs, as well as limits the use of cork-based materials due to perceived mechanical limitations of cork in providing tensile and bending strength for panel connection.
Innovation Solution
A laminated cork-based panel design without wood material, featuring a coupling member made of cork or cork-based material extending from a central cork layer, allowing for connection to similar panels, with a vertical projection and thickness optimized for structural integrity and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a structural wood layer is used in laminated flooring panels to provide coupling members for panel connection, then the panel achieves sufficient tensile strength and bending strength for assembly, but the panel weight and production costs increase
Solution Approach 1:
The patent extracts and eliminates the wood structural layer from the laminate composition, retaining only the essential cork-based layers needed for acoustic insulation and panel structure. The coupling members are formed directly from the cork-based composite layers through compression molding, removing the need for separate wood structural components while maintaining assembly functionality.
Solution Approach 2:
The patent changes the material composition parameters by formulating a cork-based composite material with sufficient mechanical properties to replace wood. By adjusting the cork particle size distribution, binder content, and compression molding parameters, the cork-based layers achieve the necessary tensile and bending strength to serve as both structural and coupling elements.
2Reliability
If a structural wood layer is used in laminated flooring panels to provide coupling members, then effective panel connection is achieved, but production costs increase
Solution Approach 1:
The patent merges the functions of the structural layer and coupling members into a single integrated cork-based composite structure. The coupling members are formed directly within the cork-based layers during the compression molding process, eliminating the need for separate wood structural layers and reducing the number of manufacturing steps and material handling operations.
Solution Approach 2:
The cork-based composite layers perform multiple functions simultaneously: they provide acoustic insulation, maintain panel structural integrity, and form integral coupling members for panel connection. This multi-functionality eliminates the need for specialized wood structural layers dedicated solely to providing coupling members.
3Ease of manufacture
If traditional laminated panel design with wood layer is used, then coupling members can be formed integrally, but the design limits the use of cork-based materials due to perceived mechanical limitations
Solution Approach 1:
The patent changes the material parameters by developing a cork-based composite formulation with optimized particle size distribution, binder content, and density that achieves sufficient mechanical strength. This enables cork-based materials to be used in applications previously reserved for wood, including integral coupling member formation through compression molding.
Solution Approach 2:
The patent uses composite materials by combining cork particles with appropriate binders and additives to create a cork-based composite with enhanced mechanical properties. This composite material can be compression molded to form integral coupling members, demonstrating that cork-based materials can replace wood in structural and connection applications.
Data Source
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AI summary
The present invention relates to a laminated panel (1) of cork material or cork-based material devoid of any wood material, the panel (1) comprising at least one central layer (2) of cork material or cork-based material, said central layer (2) having a first face and a second face; at least one wear outer layer (4) arranged on said first face of central layer (2); and one coupling member (3) arranged on at least two sides of panel (1), wherein the coupling element (3) is an extension of said central layer (2) of cork material or cork-based material at said sides. In addition, the panel further comprises a base outer layer (5) arranged on the second face of central layer (2). The invention is generally directed to building industry, and particularly it is applicable to flooring.