Floorboards With Overlapping Edges And Moisture-Resistant Grooves
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Solution Overview
Problem
Existing floorboards with resilient surface layers and decorative grooves face limitations in bevel size and moisture penetration, leading to inadequate visibility and protection of the moisture-sensitive core, especially in high-dirt and wet environments.
Innovation Solution
The development of moisture-proof floorboards with a resilient surface layer featuring a decorative groove that can be wide and watertight, combined with a mechanical locking system and sealing means, such as horizontally extending protrusions and sideways open grooves with sealing agents, to prevent moisture penetration and enhance aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the bevel is made larger to increase visibility of the decorative joint portion, then the aesthetic appeal is improved, but the bevel extends down to the moisture sensitive core causing moisture penetration
Solution Approach 1:
The floorboard structure is segmented into distinct functional layers: a moisture-resistant core and a separate resilient surface layer. The decorative groove is confined to the resilient layer, creating a visual joint effect without exposing the core to moisture. This segmentation allows the decorative function to be separated from the structural protection function.
Solution Approach 2:
The resilient surface layer acts as an intermediary between the decorative groove and the moisture-sensitive core. It provides a platform for creating visible decorative joints while preventing moisture from reaching the core, thus mediating between aesthetic requirements and moisture protection needs.
2Quantity of substance
If the resilient surface layer is made thinner to reduce material cost, then the manufacturing cost is reduced, but the bevel becomes barely visible reducing aesthetic appeal
Solution Approach 1:
The invention changes the parameter of resilient layer thickness to an optimal range that balances visibility and cost. By specifying a thickness range (0.5-3mm) and configuring the groove depth relative to this thickness, the design ensures visible decorative joints while controlling material usage and cost.
3Illumination intensity
If both joined and adjacent edges are provided with bevels to increase total width of decorative joint portion, then the aesthetic appeal is improved, but the complexity of manufacturing increases
Solution Approach 1:
The resilient surface layer serves multiple functions: it provides the decorative groove for aesthetic joints, acts as a moisture barrier, and enables the mechanical locking system. By making the resilient layer universally functional across all edges, the design achieves aesthetic appeal without proportionally increasing manufacturing complexity.
4Illumination intensity
If the decorative groove is made wider to improve visibility, then the aesthetic appeal is improved, but moisture can penetrate more easily into the joint
Solution Approach 1:
The resilient surface layer functions as a flexible moisture-resistant film that can accommodate wide decorative grooves. This flexible barrier material maintains moisture protection even when wide grooves are cut into it, allowing the groove to serve its aesthetic purpose without compromising the moisture barrier function.
Data Source
AI summary
A set of essentially identical floorboards each including a front face and a rear face extending in the horizontal plane, a core, and a surface layer, a mechanical locking system is arranged at least at two opposite edges for connecting a floorboard with an adjacent floorboard in a horizontal and a vertical direction, said mechanical locking system being configured for connecting the floorboard with the adjacent floorboard by vertical folding, wherein one of said opposite edges is provided with a horizontally extending protrusion at an upper edge, and wherein said protrusion is configured to overlap a surface groove at an upper edge of the other of said opposite edges, such that two connected and adjacent floorboards have upper overlapping edges.