Flooring Panel With Composite Core And Impressed Cavities
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Solution Overview
Problem
Rigid floor panels, such as SPC, offer superior dimensional stability and impact resistance but have unsatisfactory acoustic performance, while flexible WPC panels provide better sound absorption but are less dimensionally stable. There is a need for a flooring product that combines the benefits of both with improved acoustical performance without compromising rigidity or weight.
Innovation Solution
A panel with a composite core layer comprising at least 20% mineral material and featuring a plurality of impressed cavities on its bottom surface, which enhances acoustic performance by reducing sound transmission and reflection, and maintains rigidity and stability through the use of a composite material with a high mineral content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solid core SPC is used, then dimensional stability and impact resistance are improved, but acoustic performance deteriorates
Solution Approach 1:
The patent applies porous materials by incorporating a foam layer within the panel structure. This foam layer creates a porous structure that absorbs sound waves, reducing sound transmission and improving acoustic performance. The porous foam material allows the panel to maintain rigidity and dimensional stability while adding sound absorption capabilities that solid core SPC lacks.
Solution Approach 2:
The patent uses composite materials by combining multiple layers including a foam layer, decorative layer, and core layer. This composite structure integrates the dimensional stability of SPC with the sound absorption properties of foam materials, creating a multi-functional panel that resolves the contradiction between structural performance and acoustic performance.
2Strength
If filler or mineral content is increased, then rigidity and dimensional stability are improved, but acoustic performance deteriorates
Solution Approach 1:
The foam layer introduces porosity into the panel structure, which absorbs sound energy through viscous losses and thermal conduction within the porous structure. This porous architecture provides sound absorption without requiring a reduction in mineral content, thereby maintaining rigidity while improving acoustic performance.
Solution Approach 2:
The composite construction with foam layer integrated between decorative and core layers creates a multi-layer system where each layer performs its specialized function. The mineral-rich core provides rigidity, while the foam layer provides sound absorption, resolving the trade-off between strength and acoustic performance.
3Object-affected harmful factors
If WPC is used, then acoustic performance is improved, but dimensional stability deteriorates
Solution Approach 1:
The patent employs composite materials by layering foam (for acoustic performance) with SPC core (for dimensional stability). This composite approach allows the panel to achieve the acoustic benefits of flexible materials while maintaining the dimensional stability of rigid SPC, avoiding the drawbacks of pure WPC construction.
Solution Approach 2:
The foam layer is strategically positioned within the panel structure where it is needed for sound absorption, while the SPC core maintains dimensional stability. This local differentiation of material properties allows each material to perform its optimal function without compromising the other.
4Object-affected harmful factors
If underlay or acoustic pad is added, then acoustic performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the acoustic pad function directly into the panel structure by integrating a foam layer between the decorative layer and core layer. This consolidation eliminates the need for separate underlay or acoustic pad installations, reducing device complexity while maintaining acoustic performance benefits.
Solution Approach 2:
The integrated foam layer serves multiple functions within the panel: sound absorption, structural bonding interface, and part of the overall panel thickness. This multi-functionality reduces the need for additional separate components, simplifying the overall system while improving acoustic performance.
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 panel achieves improved sound dampening effects, potentially eliminating the need for additional sound-dampening layers, while maintaining rigidity and stability, allowing for effective sound wave attenuation across a broader range of frequencies and reducing sound amplitude by up to 5 dB compared to solid core flooring panels.
Implementation Method 1
The plurality of impressed cavities is configured to attenuate sound waves
Implementation Method 2
reduction of amplitude when tested for reflected walking sound (the sound heard in the same room)
Data Source
AI summary
The invention relates to a panel for constructing a floor or wall covering. The panel comprises a substantially planar top surface, at least one core layer composed of a composite material which core layer is provided with the cavities, and a bottom surface. The panel further comprises at least one pair of opposite edges, said pair of opposite edges preferably comprising complementary coupling parts configured for mutual coupling of adjacent panels.