Laminate Floor Panel Density Peak Layer Noise Reduction
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Solution Overview
Problem
Existing laminate floor panels produce undesirable tapping noises and have high residual tensile stresses due to the use of melamine resin, which can lead to fracture and require high substrate density to withstand these stresses.
Innovation Solution
A sheet material with at least two layers, where the first layer is primarily composed of wood particles bonded with a thermosetting binder, and the second layer is composed of particulate particles bonded with a thermoplastic and/or elastomeric binder, which is applied on the surface to reduce noise and improve structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If melamine resin is used in the top layer, then the top layer gains strength and durability, but residual tensile stresses develop leading to fracture risk and requiring high substrate density
Solution Approach 1:
The patent changes the material parameters of the substrate by creating a density peak layer with significantly higher density (0.9-1.2 g/cm³) compared to the base layer (0.6-0.8 g/cm³). This parameter change in density distribution allows the substrate to withstand the residual tensile stresses from the melamine resin without fracturing, while using a lower overall density substrate than conventional HDF boards.
Solution Approach 2:
The substrate is constructed as a composite material with two distinct layers: a base layer of compressed wood fibres and a density peak layer with higher density. This composite structure combines the advantages of low overall density with localized high density regions that can handle mechanical stresses, resolving the contradiction between strength requirements and harmful stress accumulation.
2Reliability
If a density peak occurs on the surface of MDF or HDF board, then the risk of fracture in the top layer is reduced, but irritating sounds are produced in a specific frequency range
Solution Approach 1:
The density peak layer is positioned locally at the interface between the substrate and the top layer, rather than distributing density uniformly throughout the substrate or creating surface irregularities. This localized high-density region provides fracture resistance where needed while maintaining a smooth overall surface that does not generate irritating sounds during panel movement.
3Object-generated harmful factors
If a sound-damping layer is laminated under the printed decorative skin, then tapping noises are reduced, but impact strength is reduced and the layer may crack under deformation
Solution Approach 1:
The density peak layer serves as an intermediary between the top layer and the base layer, providing both structural support and noise reduction functions. Rather than adding a separate sound-damping layer that would compromise impact strength, the density peak layer inherently dampens sounds through its high density while maintaining the overall structural integrity and impact resistance of the panel.
4Shape
If the fibre mat is heated non-uniformly during pressing, then a density peak arises on the surface, but this creates problems during pressing when deep structural elements are to be formed
Solution Approach 1:
The substrate is segmented into two distinct layers with different density characteristics: a base layer for overall structure and a density peak layer for localized stress management. This segmentation allows the density peak to be created in a controlled manner during pressing without creating the uniform surface hardening problems that prevent formation of deep structural elements.
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 proposed sheet material significantly reduces the irritating noise typically associated with laminate floor panels while maintaining mechanical strength, and allows for smooth structuring and potential spring-back during deformation, similar to real wood.
Implementation Method 1
the second layer of material is present on the surface of the sheet material and is mainly built up from particulate particles glued by means of a second binder and pressed, wherein the second binder is thermoplastic and/or elastomeric
Implementation Method 2
a first layer of material forms more than half of the thickness of the sheet material and is mainly built up from wood particles glued by means of a first binder and pressed, wherein the first binder is thermosetting
Implementation Method 3
the use of particulate particles bonded with a thermoplastic and/or elastomeric binder on the surface of a sheet material that is further bonded by means of a thermoset, the tapping noise produced by said sheet material is very similar to that of real wood
Data Source
AI summary
Sheet material includes at least two layers of material, wherein a first layer of material forms more than half the thickness of the sheet material and is mainly built up from wood particles glued by means of a first binder and pressed. The first binder is thermosetting, wherein the second layer of material is present on the surface of the aforementioned sheet material and is mainly built up from particulate particles glued by a second binder and pressed. The second binder is thermoplastic and/or elastomeric.