Floor Panel Impregnated Paper Layer for Acoustic and Haptic Improvement
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Solution Overview
Problem
Wood-based floor panels suffer from inadequate acoustic and haptic properties, leading to annoying sound pollution and an uncomfortable, cold feel, which is not suitable for applications in damp areas like kitchens and bathrooms.
Innovation Solution
A wood material panel comprising a carrier board with impregnated paper layers containing a composition of formaldehyde resin, selected polymers, and a silane compound, which enhances elasticity, friction, and impact resistance, while maintaining transparency and allowing for various decorative options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If melamine resin coating is used on floor panels, then water resistance and durability are improved, but acoustic properties deteriorate and haptic feel becomes uncomfortably cool and hard
Solution Approach 1:
The patent applies composite materials by combining melamine resin with elastomeric materials in the paper layer composition. This creates a multi-phase composite structure where the melamine resin provides water resistance and durability, while the elastomeric material provides acoustic damping and improved haptic properties. The composite approach allows simultaneous achievement of contradictory properties through material synergies.
Solution Approach 2:
The patent changes the physical and chemical parameters of the paper layer by impregnating it with a composition containing elastomeric materials. This transforms the rigid paper structure into a more compliant, elastic layer that can absorb sound vibrations while maintaining its water-resistant properties through the melamine resin matrix.
2Reliability
If melamine resin coating is used on floor panels, then water resistance is improved, but haptic properties deteriorate with an uncomfortably cool and hard feel
Solution Approach 1:
The patent creates a composite material system combining melamine resin (for water resistance) with elastomeric materials (for improved haptic properties). The elastomeric components provide a warmer, softer feel while the melamine resin ensures water resistance, achieving both requirements simultaneously through material composition rather than compromise.
3Object-affected harmful factors
If elastomeric coating is applied to improve acoustic and haptic properties, then sound absorption and feel are improved, but water resistance deteriorates
Solution Approach 1:
The patent resolves this contradiction by creating a composite where elastomeric materials are embedded within a melamine resin matrix. The melamine resin acts as a water-resistant binder that encapsulates the elastomeric particles, allowing the elastomer to provide acoustic damping while the resin network maintains water resistance. This composite structure allows both functions to coexist without compromising either property.
4Ease of operation
If filler materials such as cellulose fibers or hollow spheres are integrated into melamine resin surfaces, then haptic properties are improved, but acoustic properties remain insufficient
Solution Approach 1:
The patent changes the fundamental parameter of the paper layer by impregnating it with elastomeric materials rather than just adding surface fillers. This transforms the entire paper layer into a compliant, sound-absorbing structure with improved haptic properties, rather than merely adding filler particles to the surface. The elastomeric impregnation provides both haptic and acoustic benefits simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly improves the acoustic and haptic properties, providing a warm, velvety feel and increased impact resistance, reducing footfall noise by up to 20% and allowing for use in damp areas with enhanced water resistance.
Implementation Method 1
the hydrolysis product thereof, wherein X is H, OH or a hydrolyzable radical
Implementation Method 2
The hydrolysis and/or condensation of the compounds of the general formula (I) is caused and influenced by the reaction conditions
Implementation Method 3
at least one composition comprising at least one formaldehyde resin (or amino resin), at least one polymer selected from a group consisting of polyacrylates, polyepoxides, polyesters, polyurethanes and long-chain silanols, and at least one silane-containing compound
Data Source
Figure 1
AI summary
The present invention relates to a wood-based panel, in particular a floor panel, comprising at least one carrier board and at least one paper layer arranged on at least one side of the carrier board, wherein the at least one paper layer comprises at least one composition comprising at least one formaldehyde resin, at least one polymer selected from the group consisting of polyacrylates, polyepoxides, polyesters, polyurethanes and long-chain silanols, and at least one silane-containing compound of the general formula (I) RaSiX(4-a) (I), and/or its hydrolysis product, wherein - XH, OH or a hydrolyzable residue is selected from the group consisting of halogen, alkoxy, carboxy, amino, monoalkylamino or dialkylamino, aryloxy, acyloxy, alkylcarbonyl, - R a non-hydrolyzable organic residue R is selected from the group consisting of alkyl, aryl, alkenyl, substituted and unsubstituted alkynyl, cycloalkyl,which may be interrupted by -O- or -NH-, and - wherein R may have at least one functional group Q selected from a group containing a hydroxy, ether, amino, monoalkylamino, dialkylamino, anilino, amide, carboxy, mercapto, alkoxy, aldehyde alkylcarbonyl, epoxide, alkenyl, alkynyl, acrylic, acryloxy, methacryl, methacryloxy, cyano, and isocyano group, and - a = 0, 1, 2, 3, in particular 0, 1, or 2. is impregnated.