Two-layer floorboard with angled lower layer joints
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Solution Overview
Problem
Existing two-layer floorboards with a solid wood lamella upper layer and a wood board lower layer face limitations in length due to high raw material costs and material wastage, as well as deformities from differing layer properties, and are technologically constrained by the available lengths of raw materials.
Innovation Solution
The production of two-layer floorboards with a solid wood lamella upper layer and a lower layer composed of interconnected wood board elements, where the connection lines form angles between 30-80° with the side edges, allowing for the creation of boards of unlimited and easily changeable lengths without compromising strength, using a combination of gluing and various joint types such as scarf, tongue and groove, and shiplap joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the length of floorboards is increased to reduce the number of joints and improve continuity, then the visual appearance and structural performance improve, but the availability of raw materials of sufficient length is limited and costs increase
Solution Approach 1:
The floorboard is divided into an upper layer and a lower layer that can be manufactured separately and then joined together. The upper layer consists of solid wood lamellae of standard length, while the lower layer is made of wood board elements that can be extended. This segmentation allows each layer to be optimized independently for material availability and structural requirements.
Solution Approach 2:
The floorboard uses a composite structure with two different materials: solid wood for the upper layer providing aesthetic and surface properties, and wood board elements for the lower layer providing structural support and extendability. This composite approach combines the advantages of different materials to overcome the limitations of using a single material type.
2Device complexity
If the lower layer is made as a single piece to match the upper layer length, then structural simplicity is maintained, but material waste increases due to unreasonable cut-offs when raw material length does not match
Solution Approach 1:
The lower layer is segmented into multiple wood board elements that can be connected together. This allows the lower layer to be constructed from standard-length materials without requiring costly custom-length raw materials, thereby reducing material waste while maintaining structural integrity through the connection elements.
3Strength
If the upper and lower layers are glued together along their entire length, then bonding strength is maximized, but deformities occur due to different properties of the layers
Solution Approach 1:
The continuous gluing interface is segmented into discrete connection points between corresponding elements of the upper and lower layers. This segmentation allows each local joint to accommodate differential movement and dimensional changes, reducing the risk of deformities while maintaining sufficient overall bonding strength through multiple distributed connection points.
4Adaptability or versatility
If the length of floorboards is extended beyond standard raw material lengths, then product versatility and customer options increase, but production costs increase due to need for specially produced materials
Solution Approach 1:
The floorboard system is segmented into modular upper and lower layers that can be manufactured using standard-length raw materials and then assembled to create extended lengths. This modularity allows flexible production of various lengths without requiring expensive custom-length raw materials, maintaining ease of manufacture while increasing product versatility.
Data Source
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AI summary
The invention relates to the production of construction materials. The invention gives the possibility of producing two-layer floorboards of unlimited and easily changeable length, and also use raw materials almost fully. The two-layer floorboard includes a glued together upper layer (1) made of rectangular elements of solid wood lamella (3), which are connected along the line (4), which is perpendicular to side edges (7) of the floorboard, and lower layer (2) made of wood board elements (5), which are connected along a line (6) which forms a 30-80° angle (8) with side edges (7) of the floorboard.