Floor Board Coupling Zones for Creak-Free Moisture Resistance
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Solution Overview
Problem
Existing floor boards made of wood-based materials like MDF or HDF often produce creaking noises due to mutual tilting and deformation of coupling parts when walked upon, and are prone to moisture damage.
Innovation Solution
The floor boards feature angled coupling parts with specific contact zones and water-resistant treatments to minimize noise and moisture ingress, using mechanical coupling parts with angled tongues and lips that create multiple contact zones and water barrier agents on the edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tongue and groove coupling parts are used, then mechanical coupling is achieved, but creaking noises occur due to mutual tilting and deformation when walked upon
Solution Approach 1:
The coupling part is divided into multiple contact zones (first contact zone, second contact zone, third contact zone) along the longitudinal direction. Each contact zone provides independent support points that distribute mechanical stresses and prevent mutual tilting between adjacent floor boards, thereby eliminating creaking noises while maintaining coupling stability.
Solution Approach 2:
Different sections of the coupling part have different geometric configurations tailored to specific functions: the first contact zone has a specific profile for initial engagement, the second contact zone provides intermediate support, and the third contact zone ensures final stabilization. This localized optimization of geometry at each contact zone prevents deformation and reduces noise.
2Ease of manufacture
If wood-based materials like MDF or HDF are used for substrate, then manufacturing ease and cost-effectiveness are improved, but moisture resistance deteriorates
Solution Approach 1:
The floor board employs a composite structure combining wood-based substrate (MDF or HDF) with a decorative surface layer and edge sealing elements. This multi-layer composite construction maintains the manufacturing advantages of wood-based materials while adding protective layers that provide moisture resistance, thereby resolving the contradiction between ease of manufacture and moisture protection.
Data Source
AI summary
A floor board including a decorative surface layer applied to a substrate, where the substrate is optionally MDF or HDF material at a side edge thereof, and at least one side edge together with a side edge opposite thereto forming a first pair of opposite side edges of said substrate. The first pair of opposite side edges includes mechanical first and second coupling parts, respectively, allowing the floor board to couple at the respective side edges with a similar floor board. Also, a floor board covering consisting of a plurality of the floor boards connected to one another, and a method for manufacturing such floor boards.