Decorative Panel Chamfer with Multi-Angle Contour
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Solution Overview
Problem
Existing decorative panels with thin wear layers struggle to maintain a prominent demarcation line and adequate edge protection due to shallow chamfer angles, which are difficult to achieve with thinner wear layers while maintaining aesthetic appeal and hiding imperfections.
Innovation Solution
A decorative panel design featuring a chamfer with multiple surface contour regions of different inclinations, where the first angle is steep like traditional chamfers, and the second angle is less steep, allowing for a wider chamfer in thinner wear layers, effectively disguising edge imperfections and maintaining a cleanable groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thinner wear layer (e.g., 0.20 mm) is used to reduce material costs, then material cost decreases, but the chamfer angle becomes too shallow (e.g., 4°) to provide a prominent demarcation line and adequate edge protection
Solution Approach 1:
The chamfer surface contour is segmented into multiple regions with different inclination angles. The first region has a steeper angle (e.g., 11°) to provide a prominent demarcation line, while the second region has a shallower angle to extend the chamfer width adequately in thin wear layers. This segmentation allows the chamfer to fulfill both aesthetic and functional requirements despite limited material thickness.
Solution Approach 2:
Different portions of the chamfer are given different local qualities in terms of inclination angle. The first surface contour region has a steeper local quality to create visual prominence, while the second region has a shallower local quality to provide sufficient width for edge protection and imperfection disguise. This local differentiation resolves the contradiction between thin overall thickness and adequate chamfer functionality.
2Length of stationary object
If a shallower chamfer angle is used in thinner wear layers to maintain adequate width, then chamfer width is sufficient, but the demarcation line between the planar upper surface and chamfer becomes less prominent
Solution Approach 1:
The chamfer is segmented into at least two surface contour regions: a first region with a steeper inclination angle that creates the prominent demarcation line, and a second region with a shallower angle that extends the overall chamfer width. This segmentation allows both wide coverage and visual prominence to coexist in thin wear layers.
Solution Approach 2:
Instead of relying solely on a single angle to achieve both width and prominence, the solution introduces a multi-dimensional surface contour with varying angles. This creates a more complex three-dimensional chamfer profile that accomplishes what a single-angle chamfer cannot in thin materials.
Data Source
Figure 1~10
Figure 3~4
Figure 5~7
AI summary
A decorative panel is disclosed comprising a substrate (20) and a top layer (22) affixed to the substrate. The top layer (22) comprises a wear layer (26), the wear layer having an upper surface (28) and a chamfer (30) having a surface contour (32) extending from said upper surface (28) to an edge (12-14; 16-18) of the decorative panel (10). The surface contour (32) of the chamfer has a first surface contour region (34) extending from the upper surface (28) and a second surface contour region (36) extending from the first surface contour region (32) towards the edge (12-14; 16-18) of the decorative panel. The first surface contour region (32) has a first angle of inclination (A1) with respect to the upper surface (28) and the second surface contour region (36) has a second angle of inclination (A2) with respect to the upper surface (28). The first angle of inclination (A1) is greater than said second angle of inclination (A2).