Floor Panel Enhancement Component Thickness Variation
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Solution Overview
Problem
Existing floor panels made with thermoplastic synthetic materials often lack a natural appearance, especially when viewed from different angles or under varying light conditions, due to the use of thick transparent components with uniform finishes.
Innovation Solution
The floor panel design incorporates a substrate, a decorative layer, and a transparent component, with an enhancement component applied to the upper surface of the transparent component. The enhancement component has varying thickness along the cross-section of the floor panel, providing a more natural look by influencing the visual appearance from different angles and light conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick transparent component is provided with a uniform lacquer and relief finish, then the wear resistance is improved, but the natural appearance is lost when viewed from different angles and light conditions
Solution Approach 1:
The patent applies different finish characteristics to different regions of the transparent component. The enhancement component is applied with varying thickness across the surface, creating local variations in optical properties. This allows certain areas to maintain higher gloss for wear resistance while other areas provide more natural light diffusion, resolving the contradiction between uniform wear protection and natural appearance.
Solution Approach 2:
The enhancement component is applied asymmetrically with non-uniform thickness distribution. This asymmetric application creates varying optical effects across the surface, preventing the uniform gloss appearance that occurs with even coating. The asymmetric thickness variation allows different regions to reflect light differently, maintaining natural appearance while preserving wear resistance where needed.
2Ease of manufacture
If a uniform thickness enhancement component is applied across the entire surface, then the manufacturing process is simplified, but the visual appearance becomes unnatural when viewed from different angles
Solution Approach 1:
The enhancement component is applied with deliberately varied thickness across different regions of the transparent component. This local quality variation creates natural-looking optical effects while maintaining a relatively simple application process. The varying thickness is achieved through controlled application methods that can be integrated into existing manufacturing workflows, balancing manufacturing simplicity with aesthetic quality.
3Shape
If the transparent component is made thinner to improve natural appearance, then the visual appeal from different angles is improved, but the wear resistance and protection of the decorative layer are reduced
Solution Approach 1:
The transparent component is segmented into functional zones with different thickness characteristics. The enhancement component is applied selectively in specific regions rather than uniformly across the entire surface. This segmentation allows thinner areas to provide natural appearance while thicker areas maintain wear resistance and protective functions, resolving the contradiction between thickness and aesthetic quality.
Data Source
AI summary
A floor panel includes a substrate, a decorative layer and a transparent component. The decorative layer is positioned between the substrate and the transparent component. At least one of the substrates, the decorative layer and the transparent component has a thermoplastic synthetic material. The transparent component has an upper surface opposite the decorative layer. The floor panel further includes an enhancement component provided on the upper surface of the transparent component. A thickness of the enhancement component varies along a cross section of the floor panel.