Elastic-Core Floor Panel Structure for Impact Noise Damping

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Solution Overview

Problem

Conventional laminated floor panels struggle with high impact noise and require labor-intensive gluing processes, which are time-consuming and prone to contamination and drying issues, while plastic floor coverings offer better noise reduction but are difficult to lay quickly and efficiently.

Innovation Solution

A multilayer rectangular laminate floor panel with a soft PVC core, a décor film, a transparent finishing layer, and a counteracting layer, featuring a lockable tongue and groove profile, allowing for rapid and glue-free installation, and enhanced impact noise damping through a separate impact noise mat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional laminated floor panels with chipboard core are used, then optical appeal and ease of installation are achieved, but impact noise is high

Engineering Contradiction:

Improveimpact noiseVSAvoidnoise dampening performance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent uses a composite structure combining soft PVC core material with wood fiberboards or particle boards. This composite material approach allows the floor panel to achieve both structural integrity and superior impact noise dampening, as the soft PVC core absorbs impact noise while the rigid layers provide structural support.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameter of the core from hard chipboard to soft PVC or polyurethane material. This parameter change fundamentally alters the noise dampening characteristics, transforming the floor panel from high noise transmission to effective impact noise reduction.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If plastic floor coverings are used for better noise reduction, then impact noise damping improves, but installation becomes time-consuming and labor intensive

Engineering Contradiction:

Improveimpact noiseVSAvoidinstallation speed

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent segments the floor covering into individual panels with integrated tongue and groove profiles. This segmentation allows each panel to be installed independently through simple interlocking, eliminating the need for adhesive application and drying time, thereby dramatically increasing installation speed while maintaining noise dampening properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the chemical bonding system (adhesives) with a mechanical interlocking system (tongue and groove profiles). This substitution eliminates the time-consuming gluing and drying processes, allowing for rapid mechanical assembly while maintaining structural integrity and noise dampening performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If adhesive is used for laying floor panels, then panels are securely fixed, but contamination and drying time increase

Engineering Contradiction:

Improvepanel fixationVSAvoiddrying time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The tongue and groove profiles are pre-formed as integral parts of each panel, allowing the panels to self-lock together through simple interlocking without requiring external adhesives or additional fixing materials. This self-service approach eliminates contamination and drying time while ensuring secure panel fixation.

Inventive Principle:

Principle #25Self-service

4Ease of operation

If conventional floor panels are used, then installation is simple, but water resistance is insufficient

Engineering Contradiction:

Improveinstallation simplicityVSAvoidwater resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent uses a composite structure with soft PVC core material combined with water-resistant rigid layers (wood fiberboards or particle boards). The soft PVC material inherently provides water resistance, while the rigid layers are selected for their moisture stability, creating a composite panel that maintains both installation simplicity and superior water resistance.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides effective impact noise damping, reduces installation time and contamination, and allows for immediate use of the floor, while compensating for material shrinkage and offering water-resistance and ease of reuse.

Implementation Method 1

a soft core of plastic, especially of PVC

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

Because of its relatively soft core of plastic, especially of PVC or polyurethane, the material has a high degree of impact noise dampening

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 3

Only the UV-cured lacquer layer is applied subsequently in a separate step

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentEP4151403B1Multi-layer floor panel with elastic core

Publication Date: 2024.05.22 I4F LICENSING NV

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AI summary

A floor panel in the form of a multilayer, rectangular laminate with a soft core (10) of plastic, a decor film (12) on the upper side of the core (10), a transparent finishing layer (14) and a transparent lacquer layer (16) applied on the finishing layer (16), as well as a back-pull layer (18) on the back of the core (10), with a lockable tongue and groove connection at least at two mutually opposite edges of the panel (20, 22).