Floor Panel Coupling Bar for Dimensional Stability
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Solution Overview
Problem
Existing floor, ceiling, and wall panels face challenges such as high costs, complex installation, limited durability, and mismatched expansion behaviors between decorative and carrier materials, which are not adequately addressed by pre-finished wood or laminate panels.
Innovation Solution
A panel design featuring a base plate made from inexpensive wood composite materials with a coupling bar made from a different material, such as soft or hard wood, that extends along the panel's border with mechanical connection means like tongue and groove, allowing for easy assembly and using materials with similar expansion behavior to eliminate the need for intermediate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If veneer panels are used to achieve the attractive surface of massive wood, then the cost is reduced, but the decorative layer shows different expansion behavior than the carrier material leading to distortions
Solution Approach 1:
The patent applies local quality by using wood carrier elements specifically at the boundaries and corners of the panel, rather than throughout the entire panel. These localized carrier elements provide the necessary expansion compensation at critical locations where distortion is most likely to occur, while keeping the overall panel structure simple and cost-effective.
Solution Approach 2:
The wood carrier elements act as intermediary elements between the decorative veneer layer and the base carrier material. These intermediate wooden rods provide a transition zone that accommodates the different expansion behaviors of the veneer and base material, preventing direct stress transmission and resulting distortions.
2Stability of the object's composition
If pre-finished flooring uses thin rod-like wooden elements as carrier to compensate for expansion, then dimensional stability is improved, but the installation becomes complex and expensive requiring skilled experts
Solution Approach 1:
The patent merges the expansion compensation function with the structural support function by integrating the wood carrier elements directly into the panel assembly. The carrier elements are positioned to provide both structural support and thermal expansion compensation, eliminating the need for separate compensation mechanisms and simplifying installation.
Solution Approach 2:
The panel is segmented into functional zones with wood carrier elements placed at specific locations (boundaries and corners) where they provide expansion compensation. This segmentation allows the compensation function to be distributed to key areas without requiring complex throughout-panel integration.
3Ease of manufacture
If laminate panels are used to reduce cost and simplify installation, then the life-time is limited and the natural texture and look of wood veneer is not provided
Solution Approach 1:
The patent creates a composite structure combining multiple materials: a base carrier material (such as particle board or MDF), wood carrier elements (such as thin wooden rods or strips), and a decorative veneer layer. This composite construction provides both the installation simplicity of laminate panels and the durability and natural wood appearance of veneer panels.
4Ease of manufacture
If laminate panels use printed décor paper instead of real wood, then cost is reduced and expansion mismatch is avoided, but the natural texture and look of wood is limited
Solution Approach 1:
The wood carrier elements serve as intermediary elements that provide structural support and expansion compensation while allowing the use of real wood veneer for the decorative surface. These intermediate carrier elements enable the combination of real wood aesthetics with the dimensional stability benefits of engineered materials.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6b
AI summary
The present invention relates to a panel (20; 30; 50) for a floor, ceiling or wall covering, comprising a base plate (21; 31; 51) made from a first material having a front surface, a rear surface and a circumferential border; and at least one coupling bar (22; 32, 33; 41, 42; 54) made from a second material different from the first material. The coupling bar is provided with mechanical connection means (36, 37; 43, 44; 55) and extends along at least a portion of the circumferential border of the base plate to allow a connection with other correspondingly shaped panels (20; 30; 50). In this way a comparably inexpensive e.g. floor covering is provided.