Floor Panel Core Segmentation for Stability and Weight
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing floor panels face issues with moisture resistance, ergonomic handling, transportation, and perceived cheapness due to limited thickness and high density, which affects their stability and impression as a premium product.
Innovation Solution
A floor panel design featuring a core with a density of more than 1000 kg/m3 and a thickness of 6 millimeters or more, incorporating internal spaces and a decorative top layer, which includes a thermoplastic or mineral-based material with fillers and a cork or synthetic foam layer for enhanced stability, ergonomics, and ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the core material has high density (more than 1000 kg/m3) and limited thickness (5mm or less), then stability and resistance to compression are improved, but ergonomics during handling and transportation deteriorate
Solution Approach 1:
The core is divided into multiple layers with different densities. The lower core layer has high density (more than 1000 kg/m3) to provide stability and compression resistance, while the upper core layer has lower density (less than 1000 kg/m3) to reduce weight and improve ergonomics. This segmentation allows each layer to fulfill its specific function without compromising the overall performance.
2Stability of the object's composition
If the core material has high density (more than 1000 kg/m3), then stability is improved, but the premium appearance and perceived quality deteriorate due to limited thickness
Solution Approach 1:
The core is segmented into two layers with different thicknesses. The lower high-density layer provides stability, while the upper low-density layer increases the overall thickness to 6mm or more, creating a premium appearance and perceived quality without compromising the stability provided by the dense lower layer.
3Strength
If additional measures are taken to increase resistance to compression in foamed core material, then compression resistance is improved, but weight increases
Solution Approach 1:
The compression resistance function is assigned to the lower high-density core layer, while the upper low-density layer maintains light weight. This segmentation allows the system to achieve high compression resistance without increasing overall weight, as the dense lower layer bears the compressive loads.
Solution Approach 2:
The core uses a composite structure combining two different materials with different densities. The lower layer uses high-density material for strength and compression resistance, while the upper layer uses low-density material for weight reduction. This composite approach optimizes both strength and weight characteristics.
Data Source
AI summary
A floor panel includes a core and decorative layer applied thereon, such that the material of the aforementioned core has a density of more than 1000 kg/m3, preferably more than 1300 kg/m3, and has a thickness of 6 millimeters or more. The core has internal spaces and/or that the core has spaces on its bottom side. A method for manufacturing such floor panels is provided according to the aforementioned floor panel.