3D Printed Sealing on Floor Panel Side Surfaces
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Solution Overview
Problem
Existing methods for producing floor panels struggle with cost-effectiveness and complexity in sealing and designing the gap between panels, particularly in preventing moisture ingress and replicating realistic joint appearances, while also ensuring secure locking mechanisms.
Innovation Solution
The method involves using a 3D printer to partially or fully form the side surface of the panel with a sealing material that also serves as a decorative element, allowing for the creation of complex profiles and locking elements without the need for additional tools or separate work steps, thereby reducing costs and enhancing design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to mill locking elements and seal side surfaces, then manufacturing processes are established, but production costs increase and moisture protection is insufficient
Solution Approach 1:
The patent combines the sealing function and locking element function into a single integrated structure formed by the 3D printed side surface. The sealing protrusions and locking elements are created as one unified component during the same printing process, eliminating the need for separate sealing materials and reducing production steps while maintaining effective moisture protection and structural integrity
Solution Approach 2:
The patent replaces conventional mechanical milling processes with 3D printing technology. Instead of using CNC machines to mill locking elements and separately apply sealing compounds, the invention uses additive manufacturing to directly create the three-dimensional side surface structure with integrated sealing and locking features, reducing manufacturing complexity and cost
2Shape
If additional elements are inserted into grooves to simulate joints, then realistic joint appearance is achieved, but device complexity and sealing difficulty increase
Solution Approach 1:
The patent merges the decorative joint simulation function with the structural sealing function into a single integrated side surface design. The sealing protrusions that extend into grooves of adjacent panels simultaneously provide moisture sealing and create the visual appearance of realistic joints, eliminating the need for separate decorative elements and simplifying the overall structure
Solution Approach 2:
The side surface structure serves multiple functions simultaneously: it provides moisture sealing through protrusions that contact adjacent panels, creates locking mechanisms through integrated locking elements, and simulates realistic joint appearances through carefully designed geometric features. This multi-functionality reduces the number of separate components needed
3Reliability
If side surfaces are sealed with additional materials, then moisture ingress is prevented, but manufacturing steps increase and errors occur due to undercuts
Solution Approach 1:
The patent replaces the multi-step process of applying separate sealing materials with a single 3D printing process that creates the sealing structure as an integral part of the panel. The additive manufacturing process can create complex three-dimensional sealing geometries including undercuts and overhangs that would be difficult or impossible to achieve with conventional sealing compounds, eliminating application errors and improving manufacturing efficiency
4Strength
If locking elements are milled from core material, then strong locking mechanisms are created, but moisture can penetrate and damage the material
Solution Approach 1:
The patent uses composite material construction where the side surface with integrated locking elements is printed as a separate component from the core panel material. This allows the locking elements to be made from materials optimized for strength and moisture resistance, while the core panel can use different materials optimized for structural properties. The integrated sealing structure prevents moisture from reaching the locking elements
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
This approach enables the production of floor panels that are more cost-effective, easier to manufacture, and offer improved moisture resistance and realistic joint simulations, while providing strong and stable locking mechanisms, even in damp environments.
Implementation Method 1
one side surface (8) is at least partially formed by means of a 3D printer (200) is printed with a sealing material (28)
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The invention relates to a method for manufacturing a panel (2), in particular a floor panel, which has a top surface (4), a bottom surface (6) opposite the top surface (4) and at least one side surface (8), characterized in that the at least one side surface (8) is at least partially printed with a sealing material (28) by means of a 3D printer, wherein a part (44) of the sealing material (28) forms a part of the surface (4) of the panel (2).