Decorative Panel Edge Structure With Built-In Grout Imitation
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Solution Overview
Problem
Existing decorative panels require a grouting operation after installation to simulate the grout between tiles, which is time-consuming and can be aesthetically imperfect.
Innovation Solution
Decorative panels are designed with pre-formed recesses and lacquer layers at their edges to mimic grout, featuring visible sand or particles for a realistic imitation, eliminating the need for post-installation grouting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional ceramic or natural stone tiles are used with grout between joints, then a realistic tile appearance is achieved, but additional grouting operations are required after installation which are time-consuming and aesthetically imperfect
Solution Approach 1:
The recesses for grout imitation are pre-formed in the panels during manufacturing, and the lacquer layer with sand particles is applied in advance. This preliminary preparation eliminates the need for post-installation grouting operations, directly resolving the contradiction between achieving realistic grout appearance and the time required for additional grouting operations after installation
Solution Approach 2:
The patent creates a visual copy of grout by applying a lacquer layer containing sand particles to recesses in the panel edges. This copied grout appearance is integrated into the panel itself during manufacturing, eliminating the need for separate grouting operations and both improving aesthetic quality while reducing installation time
2Productivity
If panels are designed with pre-formed recesses and lacquer layers to mimic grout, then post-installation grouting is eliminated improving installation efficiency, but the panel structure becomes more complex
Solution Approach 1:
The patent merges the grout imitation function with the panel structure by integrating recesses and lacquer layers directly into the panel edges during manufacturing. This combination eliminates the need for separate grouting operations, improving installation efficiency while the added structural elements are incorporated as standard part of the panel fabrication process
Solution Approach 2:
The panel structure is designed to serve multiple functions: the recesses provide both structural definition and grout imitation, while the lacquer layer with sand particles provides both aesthetic appearance and tactile realism. This multi-functionality integrates the grout effect into the panel itself, improving productivity without requiring entirely separate systems
Data Source
AI summary
A panel including a substrate and a top layer. The top layer has a decor layer and a wear layer. The panel is provided with a first pair of opposite edges; and optionally with a second pair of opposite edges. At least one edge of the first pair of opposite edges is provided with a grout imitation.