Covering element
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Solution Overview
Problem
Existing floor, wall, and ceiling coverings with integrated functional components, such as sensors and actuators, often exhibit disruptive surface contours due to printed circuits and conductor tracks, which can be aesthetically and tactically undesirable.
Innovation Solution
A negative mask layer is used to compensate for the protruding contours of the functional layer, creating a smooth surface by filling gaps and accommodating protruding structures, ensuring a flat surface for further layers and providing mechanical stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a functional layer with printed circuit is integrated into the covering element, then extended functionality is achieved, but disruptive surface contours are created
Solution Approach 1:
A negative mask layer is introduced as an intermediary component between the functional layer and the visible surface. This layer contains recesses that accommodate the protruding printed circuit structures, effectively mediating between the functional requirements and the aesthetic surface requirements. The negative mask layer absorbs the surface irregularities while allowing the functional layer to maintain its electronic components.
Solution Approach 2:
The negative mask layer is designed with spatially varying properties - it has recesses in specific locations where the printed circuit protrudes, while maintaining a flat surface in other areas. This local adaptation allows the surface to be smooth where needed while accommodating functional components where required, creating a non-uniform structure that addresses both contradictory requirements in different zones.
2Volume of moving object
If the functional layer is arranged close to the surface, then space is saved, but surface contours become more visible
Solution Approach 1:
The negative mask layer serves as a mediating structure that allows the functional layer to remain close to the surface while preventing the printed circuit contours from becoming visible. The recesses in the negative mask layer capture the protruding circuit structures, creating a flat external surface that conceals the proximity arrangement of the functional layer.
3Shape
If a negative mask layer is added to compensate for contours, then surface smoothness is improved, but device complexity increases
Solution Approach 1:
The negative mask layer is integrated into the existing layered structure of the covering element, merging the contour compensation function with the overall construction. Rather than adding a completely separate system, the negative mask layer becomes part of the layered composite, combining multiple functions within a unified structural approach.
4Ease of manufacture
If protruding contours are accommodated with play, then manufacturing is easier, but mechanical stability decreases
Solution Approach 1:
The negative mask layer is designed with localized recesses that provide minimal play for the printed circuit structures. Rather than uniform tolerance throughout, the design provides precise local accommodation where needed while maintaining overall structural rigidity. This local quality approach ensures mechanical stability is preserved while allowing for manufacturing tolerances in the critical interface regions.
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a covering element (1) for a floor covering, wall covering or ceiling covering or for use as a furniture component, in particular a panel body or a sheet material, having a carrier layer (2) and having at least one functional layer (3). The invention makes provision for at least one negative-mask layer (9) to be provided for compensating for protruding contours (4), in particular from a printed circuit, of the functional layer (3), wherein the negative-mask layer (9) has at least one aperture for accommodating protruding contours (4) of the functional layer (3). The invention also relates to a method for producing a covering element (1) having a functional layer (3), with a printed circuit, and having a negative-mask layer (9) for compensating for protruding contours (4) of the functional layer (3). The invention makes provision here for the printed circuit of the functional layer (3) and for the negative-mask layer (9) to be produced in a joint process step, preferably by means of digital printing.