Floor Panel Milled Joint for Realistic Tile Appearance
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Solution Overview
Problem
Existing floor coverings with plastic cores struggle to realistically simulate a tile look with joints, as previous techniques fail to accurately reproduce wider and deeper joints.
Innovation Solution
A floor covering system where the side edge of each panel features a milling that extends into the core, creating a groove for the joint, allowing for deeper and more realistic joint representation, with optional sealing and beveled edges for a seamless transition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pressing techniques are used to create grout lines, then the manufacturing process is simple, but the joint depth and realism are insufficient
Solution Approach 1:
The milled recess is created in advance during panel manufacturing, before installation. This preliminary action allows the joint groove to be pre-formed with precise depth and dimensions, enabling deeper and more realistic joints without adding complexity to the installation process.
Solution Approach 2:
The invention replaces the conventional pressing technique (mechanical compression) with a milling operation (rotational cutting). This substitution enables the creation of deeper, more precisely controlled joints by removing material rather than compressing it, directly addressing the limitation of insufficient joint depth.
2Shape
If the visible surface layer is completely removed to expose the core, then the tile-like appearance with grout lines is achieved, but the surface protection is reduced
Solution Approach 1:
The surface layer is selectively removed only in the specific location where the joint groove is needed, while the rest of the panel surface retains its full protective surface layer. This local modification achieves the desired joint appearance without compromising the overall surface protection and durability of the panel.
3Manufacturing precision
If a milled recess extending into the core is created, then realistic grout line depth and contrast are achieved, but the manufacturing time increases
Solution Approach 1:
The milling operation that creates the joint groove is combined with the existing panel manufacturing process. By integrating the recess formation into the core production line, the joint is created in the same manufacturing cycle as the panel itself, minimizing additional time and maximizing efficiency.
Data Source
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AI summary
The floor covering (10) comprises panels (112,114) comprising a core of plastic material, and a cover layer (24) covering the upper side of the core and having complementary and mutually engaging locking profiles (120) at their connected lateral edges. At least one of the panels includes a milled-out portion (160) at the upper side of a lateral edge, with the cover layer being excavated completely over a width of the milled-out portion, so that the bottom of milled-out portion is formed by the material of the core and a groove is formed between two the connected panels. An independent claim is included for a method for manufacturing panel of floor covering.