End-Grain Step Refurbishment Element with Composite Carrier
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Solution Overview
Problem
Existing staircase renovation methods compromise the appearance and wear resistance of wooden steps, as they either cover the original surface or fail to provide sufficient resilience due to uneven substructures and deflections under load.
Innovation Solution
A refurbishment element comprising an end-grain top layer and a high-tensile carrier layer, connected via a material-to-material bond, which absorbs transverse shear forces and provides enhanced wear resistance while maintaining the real wood appearance, using materials like metal plates or HPL for the carrier layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a leveling compound or filling compound is applied to the step surface, then the worn area is filled and the step surface is restored, but the original wooden surface is covered and the visual appearance is fundamentally changed
Solution Approach 1:
The step surface is divided into two functional layers: a carrier layer that provides structural support and wear resistance, and a top layer that provides the visual appearance. This segmentation allows each layer to fulfill its specific function without compromising the other, resolving the contradiction between restoration and appearance preservation.
Solution Approach 2:
The invention uses a composite structure combining a carrier layer (made of materials like HPL or metal plates) with a top layer (made of wood or wood-like materials). This composite material approach allows the carrier layer to provide structural integrity while the top layer maintains the aesthetic appearance, solving the contradiction between surface restoration and visual appearance.
2Reliability
If a wooden panel is attached to the worn step, then the step surface is restored, but the panel lacks resilience and occurs deflections under load due to uneven substructure
Solution Approach 1:
The carrier layer is made of a composite material (HPL or metal plate) that provides high tensile strength and resilience. This composite carrier layer absorbs the deflections and stresses from uneven substructures, preventing the top layer from occurring deflections under load while maintaining restoration reliability.
Solution Approach 2:
The invention changes the material parameters of the carrier layer to have high tensile strength and elasticity, allowing it to accommodate uneven substructures and absorb stresses. This parameter change in the carrier layer's material properties ensures resilience and prevents panel deflections while maintaining step restoration.
3Device complexity
If the top layer is made of long wood, then the structure is simple, but the pressure resistance and abrasion resistance are insufficient for heavily frequented areas
Solution Approach 1:
The top layer uses end-grain wood which has superior pressure and abrasion resistance compared to long wood, while the carrier layer provides additional structural support. This composite approach maintains relative structural simplicity while significantly improving the strength and wear resistance for heavily frequented areas.
Solution Approach 2:
The invention changes the grain orientation parameter of the wood from longitudinal (long wood) to transverse (end-grain wood). This parameter change in wood grain orientation provides many times higher pressure resistance and abrasion resistance, solving the contradiction between structural simplicity and wear resistance.
4Strength
If a thick top layer is used to ensure wear resistance, then the surface is more durable, but the overall height of the renovation element increases and renovation time is extended
Solution Approach 1:
The carrier layer is made of a high-strength composite material (HPL or metal plate) that provides excellent wear resistance and structural integrity in thin profiles. This allows the top layer to be made thinner while still achieving sufficient wear resistance, thereby reducing renovation time without compromising durability.
Solution Approach 2:
The invention changes the material composition and strength parameters of the carrier layer to provide high wear resistance in a thin profile. This parameter change allows reducing the overall thickness of the renovation element, thereby reducing renovation time while maintaining sufficient wear resistance for the step surface.
Data Source
Figure 1
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AI summary
The element has an upper layer (1) designed as an end grain layer, and a carrier layer (2) designed as a tight-connection reinforcement layer i.e. metal plate. The upper layer has a firmly-bonded, planar connection (3) with the carrier layer such that transverse sliding forces are transferred between the upper and carrier layers. The upper layer has thickness in the range of 2 to 12 mm, and the carrier layer is made from fiber-composite material or high pressure laminate-material, where an upper surface of the upper layer is impregnated in a water and/or dirt-repellent manner.