Decorative Panel Core Structure for Lower Weight and Stability
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Solution Overview
Problem
Existing decorative panels face issues such as ergonomic challenges during installation, high weight leading to increased fuel consumption, and environmental impact due to transportation, along with potential strength and stability concerns, especially in moisture-resistant alternatives.
Innovation Solution
The decorative panels incorporate a first substrate layer with recesses, indentations, and/or spaces, and optionally a second unaltered substrate layer, combined with a corrugated layer, to achieve reduced weight and improved stability, using thermoplastic materials with varying compositions and densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high density core material is used to ensure stability, then stability is improved, but weight increases leading to ergonomic problems and high fuel consumption
Solution Approach 1:
The substrate layer is designed with recesses, indentations and/or spaces creating a porous structure that reduces weight while maintaining stability. The porous configuration allows the panel to be lighter and easier to handle during installation and transportation, while the remaining material structure preserves the necessary mechanical stability.
Solution Approach 2:
The substrate layer is segmented into multiple regions through the recesses, indentations and/or spaces, creating a structured pattern that distributes mechanical loads more effectively. This segmentation allows weight reduction while maintaining overall panel stability through the distributed structural support.
2Weight of moving object
If substantial voids are introduced in substrate material to reduce weight, then weight is reduced, but strength and stability deteriorate
Solution Approach 1:
The recesses, indentations and/or spaces are strategically positioned within the substrate layer rather than uniformly distributed. This local quality approach ensures that critical areas maintain full material presence for strength, while other areas are reduced to minimize weight, achieving an optimal balance between strength and weight reduction.
Solution Approach 2:
The panel employs a composite structure combining the substrate layer with the decorative top layer featuring wear layer and decorative layer. This composite construction distributes mechanical stresses across different materials and layers, maintaining overall strength even with weight-reduced substrate material containing recesses and indentations.
3Weight of moving object
If large amounts of substrate material are removed to reduce weight, then weight is reduced, but additional scrap material is generated
Solution Approach 1:
The recesses, indentations and/or spaces are incorporated into the substrate layer design from the beginning of the manufacturing process rather than being created by removing material from a solid substrate. This preliminary action approach allows the panel to be formed with the desired weight-reducing features already in place, minimizing scrap material generation during production.
Data Source
AI summary
A decorative panel includes one or more substrate layers and a top layer. The top layer has at least a decorative layer and a wear layer provided above the decorative layer. At least a first substrate layer has a plurality of recesses, indentations and/or spaces, or wherein the decorative panel further has a corrugated layer positioned on the bottom side of one of the substrate layers, such as the lowermost substrate layer.