Grooved Laminate Panel Cores for Lower Weight and Stable Locking
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Solution Overview
Problem
Existing laminated panels face challenges in reducing material and weight content while maintaining stability and strength, particularly due to the need for high-density cores to withstand pressing and support mechanical locking systems.
Innovation Solution
Incorporating core grooves on the rear side of the panels to remove material for use in upper and lower layers, combined with a locking system that includes tongue and groove configurations for vertical and horizontal locking, and using wood fibre and thermosetting resins in all layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high-density core material is used to maintain stability and strength, then structural stability is improved, but weight and material content increase
Solution Approach 1:
The core is segmented by forming grooves that divide it into multiple sections. This segmentation removes material from the core while maintaining structural integrity through the groove geometry, reducing weight and material content by up to 20% while preserving panel stability
Solution Approach 2:
The core is transformed into a porous structure through groove formation, creating void spaces that reduce material content and weight. The porous design maintains sufficient structural stability by retaining the essential core framework while eliminating excess material
2Weight of stationary object
If material is removed from the core to reduce weight, then weight and material content decrease, but structural strength may be compromised
Solution Approach 1:
Material is selectively removed from specific regions of the core through groove formation, creating areas of varying density. The local quality changes allow weight reduction in non-critical areas while maintaining strength in load-bearing regions, achieving up to 20% material reduction without compromising essential structural strength
Solution Approach 2:
The panel employs a composite structure combining the grooved core with surface layers and locking systems. This composite design distributes structural loads across different components, allowing the core to be lightweighted through groove formation while maintaining overall panel strength through the integrated composite structure
3Quantity of substance
If core material is reduced for weight savings, then material content decreases, but ability to support locking systems may be affected
Solution Approach 1:
The groove segmentation strategy strategically positions material removal away from locking system attachment zones. This selective segmentation reduces core material content by up to 20% while preserving sufficient material in critical areas to reliably support the locking system
Solution Approach 2:
The groove pattern is designed in advance to pre-position structural support elements that will later accommodate the locking system. This preliminary action ensures that even with reduced material content, the core maintains the necessary support capability for reliable locking system installation
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 reduces panel weight and material content by up to 20% while maintaining stability and enabling efficient production of high-quality locking systems, allowing for cost-effective manufacturing.
Implementation Method 1
A decorative paper 2b and a wear resistant transparent overlay paper 2a are impregnated with a thermosetting resin, such as melamine, and are applied on the upper part of a HDF core 3. The core 3 with the upper 2 and lower 4 layers is moved into a press 5 and pressed under heat and pressure such that the thermosetting resins are cured and the layers are attached to the core
Implementation Method 2
The core 3 with the upper 2 and lower 4 layers is moved into a press 5 and pressed under heat and pressure such that the thermosetting resins are cured and the layers are attached to the core
Data Source
AI summary
Building panels, especially laminated floor panels are shown, which are provided with a locking system and several core grooves at the rear side in order to save material and decrease weight. Building panels, each having a surface layer on a front side, a backing layer on a rear side and an intermediate core, wherein the intermediate core and the surface and the backing layer all comprise wood fibres and thermosetting resins, the building panels are provided with a locking system for vertical and horizontal locking of a first edge of a first building panel to an adjacent second edge of a second building panel.