Flooring Panel Edge Decoration and Moisture Sealing
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Solution Overview
Problem
Existing floor panels fail to completely imitate a natural material appearance and are vulnerable to moisture due to uncovered side surfaces, leading to a reduced quality impression and potential swelling issues.
Innovation Solution
All side surfaces, including connecting means and the underside, are decorated to match the natural material on the top surface, with a waterproof polyurethane coating applied to create a seamless and durable finish, using conventional printing inks and embossing techniques to enhance the natural material imitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the side surfaces are left uncovered to show the base material, then the manufacturing process is simple and cost-effective, but the visual impression of natural material imitation is lost and moisture can penetrate the base material
Solution Approach 1:
The patent combines the decorative function and protective function into a single integrated solution by applying a transparent protective coating that simultaneously seals the side surfaces against moisture and maintains the visual appearance of the natural material grain pattern, eliminating the need for separate decorative and protective treatments
Solution Approach 2:
The transparent protective coating preserves the natural color and grain pattern of the wood-based composite material while providing moisture protection, allowing the side surfaces to maintain their aesthetic appeal without requiring additional decorative layers or color treatments
2Reliability
If wax-containing applications are applied to locking elements, then creaking noises are avoided and hydrophobic treatment is provided, but the side surfaces cannot be completely and permanently sealed
Solution Approach 1:
The patent replaces the mechanical application method (wax-containing applications) with a more effective sealing system consisting of precisely fitted connecting means with tongue and groove profiles that create complete seals without requiring additional sealing materials or complex application processes
Solution Approach 2:
The patent changes the sealing mechanism from chemical (wax hydrophobic treatment) to mechanical (precision-fitted connecting means), achieving complete and permanent sealing through precise dimensional control of the connecting profiles rather than relying on material properties
3Reliability
If the wear layer is bent around the side edge to protect the butt edge, then the edge is coated with the decorative layer, but the locking means remain visible and the impression of perfect imitation is lost
Solution Approach 1:
The patent makes the connecting means serve dual functions: mechanically connecting panels and providing decorative coverage, by integrating the decorative layer directly onto the connecting means so they simultaneously perform structural and aesthetic roles
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 provides a nearly perfect visual and tactile imitation of a natural material while ensuring the panels are resistant to moisture and mechanical stress, reducing swelling and shrinkage, and allowing for easy, glue-free installation.
Implementation Method 1
a waterproof polyurethane coating applied to create a seamless and durable finish
Implementation Method 2
using conventional printing inks and embossing techniques to enhance the natural material imitation
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The board is made of wood material with an upper surface (1) and a lower surface (2). At least the upper surface is covered with a decorative wood grain layer. It has a tongue (5) and a groove (4) corresponding to each other, and side surfaces (7, 8). At least one side surface and the tongue and/or the groove are covered in the decorative wood grain layer.