Grooved Mineral-Based Panels With Robust Polymer Locking
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Solution Overview
Problem
There is a need for mineral-based panels that are lighter, cost-effective, and have improved sound properties, while maintaining fire resistance, water resistance, and dimensional stability, with a requirement for more robust locking systems.
Innovation Solution
A mineral-based panel design featuring a mineral-based core with grooves and a polymer-based layer, where the grooves can be formed using rotational or non-rotational processing, and a locking system that includes a strip extending horizontally beyond the panel's upper portion for enhanced flexibility and resistance to heavy loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If mineral-based panels use traditional solid structure without grooves, then they have good fire resistance and water resistance, but they are heavy and have poor sound properties
Solution Approach 1:
The patent introduces grooves into the mineral-based panel to create a porous structure. These grooves reduce the overall density and weight of the panel while the mineral-based material lining the grooves maintains fire resistance and water resistance. The porous structure also improves sound absorption properties.
Solution Approach 2:
The patent uses composite construction by combining mineral-based materials with the groove structure. The mineral-based core material provides fire and water resistance, while the groove geometry and optional polymer-based lower layer contribute to weight reduction and improved sound properties, creating a multi-functional composite panel.
2Reliability
If mineral-based panels use traditional locking systems, then they have simple structure, but they lack robustness and flexibility under heavy loads
Solution Approach 1:
The locking system is divided into multiple functional elements: a locking profile with locking arms, a locking groove, and a polymer-based lower layer. This segmentation allows each component to perform its specific function while collectively providing robust and flexible load-bearing capability.
Solution Approach 2:
The patent changes the material parameters of the locking system by introducing a polymer-based lower layer that provides flexibility and elasticity. This allows the locking system to adapt to heavy loads and maintain reliability while accommodating dimensional variations.
3Object-affected harmful factors
If grooves are added to mineral-based panels, then sound properties improve and weight reduces, but manufacturing complexity increases
Solution Approach 1:
The grooves are formed as integral parts of the panel during the manufacturing process, before final assembly. This preliminary action allows the grooves to be created efficiently using mold-based techniques or extrusion processes, reducing subsequent manufacturing complexity.
Solution Approach 2:
The patent replaces complex mechanical groove formation methods with more efficient processes such as mold-based shaping or extrusion during panel fabrication. This substitution simplifies the manufacturing process while maintaining precise groove geometry for optimal sound properties.
Data Source
AI summary
A mineral-based panel including a mineral-based core and at least one groove. The at least one groove may be provided in a rear side of the panel. The mineral-based panels may be floor panel, a building panel, a wall panel, a ceiling panel or a furniture panel. A method for forming such grooves in a mineral-based panel. Furthermore, a mineral-based panel including a mineral-based core and polymer-based lower layer(s) attached to the core. A locking system of the panel includes a strip extending horizontally beyond an upper portion of the panel, and a horizontal portion of the strip is entirely formed in the polymer-based lower layer(s).